DR. JOHN FISCHERNAVAL AIR SYSTEMS COMMAND

8 November 2006

NAVAL AVIATION S&T:Corrosion Resistant Alloys

Presentation Outline

• NAE S&T Enterprise• NAVAIR Core Products and Capabilities• Naval Aviation’s Harsh Operating

Environment: The Cost of Corrosion• Importance of this Work Shop

NAE S&T Enterprise

Naval Aviation Triad

FundsRequirements

Executes Requirements

The FleetProv

ides

Pro

duct

s /

Serv

ices

to F

leet

Generate Sorties to

M-R

ating

Requirements Met Based On Funding Availability

COMNAVAIRFOR

OPNAV HQMC

Directs / MonitorRequirements

Providers Resources

Fleet RequirementsThis is the Naval Aviation Triad showing the link between requirements, resources and providers activities.

Our $40 Billion Enterprise

$0

$10

$20

$30

$40

$50

RDT&E (Research, Development, Test & Evaluation)

Bill

ions

$

OMN,R

MPN, RPN

Procurement

Manpower

Operations

19%

37%

21%

22%

Through the Total ForceReadiness element, we can shape the force and reduce the cost of the people element.

Through the Readinesselement, we can reduce our operations and maintenance costs.

Remember the inspiration to pay for Naval Aviation’s future? By reducing the overall cost of business, we can afford a fleet for the future.

FY06

NAVY OPERATING CONCEPT(CURRENT & FUTURE READINESS)

NAE SWE USE NNFE NECC

WARFARE DOMAIN

WARFARE DOMAIN

WARFARE DOMAIN

WARFARE DOMAIN

MPT&E

PROVIDERS & ENABLERS

WARFARE DOMAIN

**NOTE: ATL INCLUDES PEOS, SYSCOMS

AT&L**

PROVIDERS / ENABLERS(SUPPORTING WARFARE ENTERPRISES)

WARFARE ENTERPRISES(DELIVERING COMBAT CAPABILITY TO COCOMS )

FYDPNEXT

NEXT +

CURRENT- - - - - - - - FUTURE

READINESS

INSTALLATIONS

HEALTH CARE

S & T

PEOPLE,

DOLLARS,

STUFF

RESOURCES AT EACHENTERPRISE INTERSECTION

• DOLLARS• PEOPLE• STUFF• CAPABILITY

OUTPUT =READINESS

COST

THE NAVAL AVIATION S&T ENTERPRISE

FLEE

T

COMBAT DEVELOPER(CNAF / OPNAV / CFFC)

• REQUIREMENTS• RESOURCES• EXPERIMENTATION

TECHNOLOGY DEVELOPER(ONR / NRL / NRE / ACADEMIA

/ INDUSTRY)• TECHNOLOGY BASE• TECHNOLOGY

DEMONSTRATION• TECHNOLOGY TRANSITION

MATERIAL / SYSTEMS PROVIDER (NAVAIR)

• S&T PLAN EXECUTION• TECHNOLOGY TRANSITION• SYSTEM DEVELOPMENT• IN-SERVICE

WARFARE CENTERS

S&T PROCESS ALIGNMENT – WHAT’S NEEDED• ROBUST NAVAL AVIATION S&T PLANNING PROCESS • EMPHASIZE REQUIREMENTS DRIVEN S&T INVESTMENTS YET FOSTER

INNOVATIVE CONCEPTS WHICH WOULD PROVIDE NEW RELEVANT WARFIGHTINGCAPABILITIES

– BALANCE OF REQUIREMENTS PULL AND TECHNOLOGY PUSH

– PROCESS TO ENABLE OPERATORS TO CONDUCT “WHAT IF” SCENARIOS ALONGSIDE TECHNOLOGISTS TO ASSESS LEADING-EDGE TECHNOLOGIES AND CREATE NEW AND INNOVATIVE TECHNOLOGY APPLICATIONS

• PRIORITIZATION PROCESS• INCREASED VISIBILITY INTO S&T INVESTMENTS WHICH BENEFIT NAVAL AVIATION• METHODS AND TOOLS TO ASSESS THE RELATIVE VALUE OF S&T INVESTMENTS

(COST, CAPABILITY, RISK)

• Desired output first, then……..

•Policies/ processesneeded to obtain outcome, lastly…..

•Behavioral constructs/ conopsto achieve cost-wise & responsive outcomes…….

Need to Define:

A Behavioral Model For the Greater Good

STEP 1“NAE S&T STRATEGIC PLAN”

A SHARED VISION WITH THEOFFICE OF NAVAL RESEARCH

FIRST STEP IN DEVELOPING AN S&T INVESTMENT STRATEGY

CNO, CMC,ASN(RDA)

Projects

S&T Strategy –Naval Aviation Enterprise/MCCDC/CNR

CNR

CapabilityGaps

Vision

S&TObjectives

ResearchAreas

Thrusts

NAE S&T STRATEGIC PLAN**SIGNED 1 JULY 2006

• ENTERPRISE ALIGNMENT• IDENTIFY GAPS & NEEDS• FOCUS OBJECTIVES• DEFINE RESEARCH AREAS• ALIGN INVESTMENTS• DEVELOP CONOPS TO SUPPORT NAE S&T VISION

THIS GUIDANCE AND VISION FROM THE CHIEF OF NAVAL RESEARCH SERVES AS THE FOUNDATION FOR THE NAE PLAN

THE CNR’S PORTFOLIO MANAGEMENT STRATEGY

ACHIEVING THE NAE S&T VISION

NAE S&T COMMUNITY*

OPERATIONALFORCES

ACADEMIAACADEMIA

INDUSTRYINDUSTRY

OTHERSERVICE

LABS

OTHERSERVICE

LABS

NATIONALLABS

NATIONALLABS

COMMUNICATE NAE NEEDS TO THE EXTERNAL TECHNICAL COMMUNITYALIGN INVESTMENTS TO NAE CAPABILITIES NEEDSFILTER TECHNOLOGY SOLUTIONS FOR NEW PROGRAM STARTS AND SYSTEM UPGRADESESTABLISH & PRIORITZE TECHNOLOGY REQUIREMENTS AND TRACK PROGRESSCONTINUALLY SCAN TECHNOLOGY HORIZON FOR NAE-RELEVANT SOLUTIONS COLLABORATE WITH EXTERNAL TECHNICAL COMMUNITY TO LEVERAGE PRODUCTS AND INVESTMENTSDEVELOP TECHNOLOGY PRODUCTS FOR NAVAL AVIATION UNIQUE NEEDSCOMMUNICATE ACROSS THE S&T CONTINUUM AND ADDRESS TECHNOLOGY ISSUESSUPPORT THE ENTIRE LIFE CYCLE OF NAE SYSTEMSSTRENGTHEN RELATIONSHIPS BETWEEN TECHNOLOGY PROVIDERS AND THE FLEET

THE NAE S&T COMMUNITY MUST OFFER NEW AND INNOVATIVE TECHNOLOGY SOLUTIONS AND PRODUCTS TO MEET THE

DEMANDS OF THE NAE’S OPERATIONAL FORCES

THE NAE S&T COMMUNITY MUST OFFER NEW AND INNOVATIVE TECHNOLOGY SOLUTIONS AND PRODUCTS TO MEET THE

DEMANDS OF THE NAE’S OPERATIONAL FORCES

*INCLUDES IN-HOUSE S&Es, ONR, DARPA, AND NRL

NAVAL AVIATION ENTERPRISE

THE S&T COMMUNITY WILL:

NAVY/NAVAIR IN-HOUSES&T PERFORMERSNAVY/NAVAIR IN-HOUSE

S&T PERFORMERS

CURRENT NAE S&T AREAS• AIR VEHICLES

– COMPUTATIONAL FLUID DYNAMICS

– STRUCTURES

– UAVS

• PROPULSION– AIRCRAFT TURBINE ENGINES

– MISSILE ROCKET MOTORS

– ELECTRICAL POWER

– ALTERNATIVE FUELS

• AVIONICS– RADAR

– ASW

– SENSORS

– ADVANCED COMMUNICATION SYSTEMS

• CREW SYSTEMS– LASER EYE PROTECTION

– EJECTION SEATS

– AIRCREW PROTECTION

– TRAINING

• WEAPONS & ENERGETICS– MISSILE / WEAPON TECHNOLOGY

– EXPLOSIVES / PROPELLANTS

– TARGETING• AIRCRAFT / SHIP INTERFACE

– ELECTROMAGNETIC LAUNCH– ADVANCED RECOVERY SYSTEMS– DECK HANDLING OF AIRCRAFT

• AIRCRAFT SURVIVABILITY• MATERIALS ENGINEERING• RESEARCH IN CHEMISTRY, PHYSICS,

AND IMAGE PROCESSING

NAVAIR Core Products and Capabilities

SEA BASED AIRCRAFT AND SYSTEMS MARITIME WEAPONS MARINE EXPEDITIONARY

AVIATION SYSTEMS

. . . MORE THAN AIRCRAFT AND WEAPONS, TOTAL SYSTEM CAPABILITY AND SUSTAINMENT

TEST ANDEVALUATION

REPAIR /MODIFICATION

IN-SERVICE ENGR &LOGISTICS SUPPORTTECHNOLOGY, R&D,HW / SW PRODUCTS

ACQUISITIONMANAGEMENT

OUR CORE PROCESSES . . .PERFORM ACQUISITION MANAGEMENT FOR THE DEVELOPMENT, PRODUCTION, AND IN-SERVICE SUPPORT OF AIRCRAFT AND WEAPONS SYSTEMS

TEST AND EVALUATE AIRCRAFT, WEAPONS AND INTEGRATED,INTEROPERABLE SYSTEMS

PROVIDE FOR THE REPAIR AND / OR MODIFICATION OF AIRCRAFT, ENGINES, SYSTEMS AND COMPONENTS

PROVIDE FOR IN-SERVICE ENGINEERING AND LOGISTICS SUPPORT

CONDUCT EFFORTS FOCUSED ON THE ADVANCEMENT OF TECHNOLOGY, RESEARCH AND DEVELOPMENT AND DELIVERY OF SOFTWARE / HARDWARE PRODUCTS

DEVELOP / MAINTAIN COMPETENCY POLICIES, PROCEDURES & SUPPORT SERVICES. FACILITATE EFFECTIVE UTILIZATION OF INFRASTRUCTURE, SECURITY, LEGAL, FINANCIAL, HUMAN & INFORMATION RESOURCES

SUPPORTOPERATIONS

AIR ASW / ASUW

AIRCREW / MAINTENANCE TRAINING SYSTEMS

CORE PRODUCTSBUSINESS WE ARE IN . . . WORK WITH INDUSTRY TO DELIVER

NAVAIR SITES

NAVAIR DEPOT,CHERRY POINT, NC

Delivers on time quality products and services for Naval aviation as service to the fleet.

Aircraft: AV-8B, Harrier; H-53, Sea Stallion; C-130, Hercules; H-46, Sea Knight; V-22, Osprey; VH-3,

Presidential Helicopter

NAVAIR DEPOT,JACKSONVILLE, FL

Delivers high quality maintenance, engineering, logistics and support

services to the fleet.

Aircraft: P-3 Orion; EA-6B Prowler, F-14 Tomcat, F/A-18 Hornet; S-3

Viking; SH-60 Seahawk

AIRCRAFT DIVISION,LAKEHURST, NJ

Provides aircraft launch and recovery expertise to the fleet.

WEAPONS DIVISION,CHINA LAKE & PT MUGU, CA

Provides our forces with effective and affordable integrated warfare systems and

life cycle support to ensure battlespacedominance.

NAVAIR DEPOT,NORTH ISLAND, CA

Provides comprehensive quality aviation support to the nation's warfighters.

Aircraft: F/A-18 Hornet; E-2C Hawkeye; C-2 Greyhound; S-3 Viking; H-60 Seahawk

TRAINING SYSTEMS DIVISION, ORLANDO, FL

Center for research, development, test and evaluation, acquisition and

product support of training systems for the world.

AIRCRAFT DIVISION,PATUXENT RIVER, MD

Provides acquisition management, research and development capabilities, air and ground test and evaluation, aircraft

logistics and maintenance management for Naval aviation.

NAVAIR/PEO’S WORKFORCE

• PRESENT # OF Ph.D.s 287• PRESENT # OF ENGINEERS 6,450• PRESENT # OF STUDENTS (TPS) 66• PRESENT # OF TOTAL GRADUATES (TPS) 3,162• PRESENT # OF ASTRONAUTS (NASA) 75• PATENTS

– HEADQUARTERS 143– NAWC (AIRCRAFT DIVISION) 396– NAWC (WEAPONS DIVISION) 396– PACIFIC MISSILE TEST CENTER 408

(NOW PART OF NAWC – WD)– NAVAL TRAINING SYSTEMS CENTER 164

TOTAL 1,507

Naval Aviation’s Harsh Operating Environment: The Cost of Corrosion

NAVY UNIQUE AIRCRAFT REQUIREMENTSNavy ship-based aircraft must do everything that land-based aircraft do. . . but in a more hostile environment and under more adverse conditions

Aircraft carrier to scale

Typical 300 X 8,000 ft runwayCATAPULT T/O AND ARRESTED LANDING• Quick, Precise Engine Acceleration

Required (500 fpm Min. SEROC)• High Impact Structural Loads

(6 Times that of Land-Based Aircraft~30% Weight Penalty)

– 27 fps Sink Rate– 0-150 mph in 2.1 Sec.

• Aircraft Weight Limited(90,000 lbs Launch/65,000 lbs Recover)

• 2 Times Demonstrated Fatigue Life

LIMITED SPACE FOR STOWAGEAND MAINTENANCE• Few Types of Aircraft• Spotting Factor (Wing, Tail and/or Blade

Folds)• On Deck Line Maintenance• Maintenance Space/Storage Limited• Commonality in Spares and Maintenance

MARITIME ENVIRONMENT• Highly Corrosive Atmosphere

– Salt Water– Exhaust Gases– High Humidity

• EMI: 240 V/m Constant; 20,000 V/m Spike

EXFOLIATION CORROSION OF ALUMINUM 7075-T6

7075-T6 Longitudinal

7075-T6 Transverse

Corrosion induced collapse of F-18 Lever Arm (300M Steel) of the Landing Gear signifies importance of corrosion prevention methodologies currently in place at NAVAIR

STRESS CORROSION CRACK

Wingfold Transmission Corrosion

• The F-18 C/D has history of severe housing lug corrosion.

Cracks

Missing Lugs

S. Spadafora and C. Matzdorf, Impact of Corrosion on the Naval Aviation Enterprise, brief 2005

Importance of this Work Shop

• PEO(A) SPONSORED A ROTORCRAFT / VERTICAL LIFT TECHNOLOGY WORKSHOP IN DECEMBER 2005

Workshop Origins

• Five discussion Groups– Performance– Interoperability – Operations & Sustainment– Safety– Survivability

• Led by NAVAIR Facilitator– Selected Audience (~30)– Guided the discussion– Note taker(s)

• Group output was consensus of rotorcraft experts– Industry, Government, Academia

• Validated list of Critical Issues.• For each issue, the specific challenges were

defined.• For each given challenge, potential technology

solutions were proposed, and time-phased.

Discussion Group Output

Operations & SustainmentCritical Issues

Near-Term (FY05 – FY09) Mid-Term (FY10-FY15) Far-Term (FY16-FY25)

•Corrosion, Erosion, and Environmental Degradation•Usage Based Maintenance

•Vibration Reduction

•Composite Fuselages and Structures

•Shipboard Landing Systems

•Avionics and Software Obsolescence

•Polluting Processes

•FOD Prevention / tolerance

•Accelerate Technology Insertion

•Manufacturing Cost Reduction

•Bearing and Lube Systems

•Data and Knowledge Management

•Corrosion, Erosion, and Environmental Degradation•Conditioned Based Maintenance

•Vibration Reduction

•Composite Fuselages and Structures

•Electric Systems

•Shipboard Landing Systems

•Avionics and Software Obsolescence

•Polluting Processes

•FOD Prevention / tolerance

•Accelerate Technology Insertion

•Manufacturing Cost Reduction

•Dynamic Component Reliability

•Engine Durability

•Bearing and Lube Systems

•Data and Knowledge Management

•Corrosion, Erosion, and Environmental Degradation•Real Time Condition based maintenance

•Vibration Reduction

•Composite Fuselages and Structures

•Electric Systems

•Shipboard Landing Systems

•Avionics and Software Obsolescence

•Polluting Processes

•FOD Prevention / tolerance

•Accelerate Technology Insertion

•Manufacturing Cost Reduction

•Dynamic Component Reliability

•Engine Durability

•Bearing and Lube Systems

Critical Issue: Corrosion, Erosion, and Environmental Degradation

General Challenges Near-Term(FY05 – FY09)

Mid-Term(FY10-FY15)

Far-Term(FY16-FY25)

•Structural Corrosion of the airframe•Hot Corrosion of engine components•Sand Erosion•Engine sand ingestion

•Nano-coating technology•Improve Corrosion resistant alloys and Structures•Improved Corrosion Protection Schemes•Corrosion detection sensing

•Multi-scale (i.e., nanomeso macro) physics-based modeling framework for prediction of structural corrosion and assessment of corrosion mitigation concepts.•Nano-coating technology•Improve Corrosion resistant alloys and Structures•Improved Corrosion Protection Schemes•Intrinsically Corrosion Resistant Materials & Structures•Corrosion detection sensing•Self-detecting, self-healing coatings•Inherently erosion resistant materials•Smart erosion-detecting and self-healing materials•Modular blade designs

•Multi-scale (i.e., nanomeso macro) physics-based modeling framework for prediction of structural corrosion and assessment of corrosion mitigation concepts.•Nano-coating technology•Improve Corrosion resistant alloys and Structures•Intrinsically Corrosion Resistant Materials & Structures•Self-detecting, self-healing coatings•Inherently erosion resistant materials•Smart erosion-detecting and self-healing materials•Modular blade designs

Critical Issues and Associated S&T Technology Challenges

SUMMARY

• NAE IS $40 BILLION ENTERPRISE THAT IS RESTRUCTURING ITS S&T PROGRAM

• NAVAIR PROVIDES A WIDE RANGE OF PRODUCTS AND SERVICES TO THE NAE

• CORROSION IS A SERIOUS PROBLEM THAT COSTS NAVAL AVIATION NEARLY $1B PER YEAR AND ACCOUNTS FOR 37% OF ALL MMH EXPENDED

• THIS WORKSHOP IS IMPORTANT BECAUSE IT WILL FORM THE LOGICAL BASIS FOR S&T WORK NEEDED TO ADDRESS THE COST OF CORROSION.