I n t e g r i t y S e r v i c e E x c e l l e n c e Air Force Life Cycle Management Center Sustainment Technologies Big Rocks 1 Mark Smallwood PE CIH AFLCMCEZP B r e a k i n g B a r r i e r s S i n c e 1 9 4 ID: 771374
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I n t e g r i t y - S e r v i c e - E x c e l l e n c e Air Force Life Cycle Management Center Sustainment Technologies“Big Rocks” 1 Mark Smallwood, PE, CIH AFLCMC/EZP
B r e a k i n g B a r r i e r s … S i n c e 1 9 4 7 2 Vision : Affordable Warfighter Readiness…Innovative Product Support Engineering Capabilities Mission: Ensure AF Enterprise Focus by Applying Airworthiness Approach that Promotes Cost-Effective Technology and Sustainment Solutions AFLCMC/EZP DNA – It’s Who We Are! We Raise the bar! C oo r d inated Requests Responsive C ustomer Focused
B r e a k i n g B a r r i e r s … S i n c e 1 9 4 7 AFLCMC/EZP Nationwide Team Frank Erdman Mark Sma ll w ood Jerry Gibson 4
Technical DisciplinesReliability & Maintainability (R&M) & Sustainment Branch Reliability Analysis, Planning, Tracking, & ReportingReliability Centered Maintenance (RCM) Condition Based Maintenance Plus (CBM+)Engineering Technical Assistance Reports (ETARs) Critical Safety Items (CSIs) Aircraft Structural Integrity Management Information System (ASIMIS) Sustainment Technology Transition Branch Airworthiness New Materials and Substitution LeadWeapon System Sustainment Technology Enterprise Program (WS-STEP)Laser De-Paint InitiativeChromium Risk Mitigation InitiativeCadmium Risk Mitigation InitiativeAF Additive Manufacturing Implementation PlanSustaining Engineering Requirements SupportAF Corrosion Technical Working GroupAircraft Battle Damage Repair Engineering (ABDRE)Center Test Authorities (CTAs)Corrosion Prevention & Control OfficeNon-Destructive Inspection OfficeAdvanced Composites OfficeMetals Technology OfficeApplied Engineering & Technology Branch Materials Handling EngineeringPackaging Technology & EngineeringProduct Support Engineering DivisionJerry Gibson Branch ChiefDebbie Naguy Division ChiefReliability Maintainability & SustainmentMark Smallwood Branch ChiefJohn Hedke Technical ExpertSustainment Technology TransitionFrank Erdman Branch ChiefMike Froning Technical ExpertApplied Engineering & TechnologyMatt Phillips Tech DirectorAFLCMC/EZP OrganizationB r e a k i n g B a r r i e r s … S i n c e 1 9 4 74
Demilitarization Acquisition Tomorrow’s Lifecycle Overview… $ R equ i r e m ent s Development $$$$$$ Maintenance & Sustainment$$$$…Bend the Cost Curve thru Enterprise Mindset!B r e a k i n g B a r r i e r s … S i n c e 1 9 4 75
The Innovation Journey Focus on Transformational Technology Areas to Support and Enhance Technology Readiness + Enable Cost Effective EngineeringKey in on Greatest Opportunities Stand up and Establish Long-Term Commitment to Enterprise “Big Rocks” Initiatives Additive Manufacturing Corrosion Prevention & ControlCondition Based Maintenance (CBM+)Robotics ApplicationsApply Crawl…Walk…Run ApproachB r e a k i n g B a r r i e r s … S i n c e 1 9 4 76
Additive Manufacturing (AM) Laying the Foundation of AM► Standardized processes & tools► Standardized equipment & machines ► Skilled technicians & engineers ► Cyber secure, centralized technical data ► Enterprise NetworkAdditive Manufacturing Strategic Implementation Plan… Leveraging AFFOCB r e a k i n g B a r r i e r s … S i n c e 1 9 4 77
Additive Manufacturing Agile Combat Support TodayDecentralized Applications Mainly Polymer Based Tomorro w Centralized Applications FutureAgile ManufacturingFixtures, tools & standsVehicles & transportationWeapons systems Engineering Application Site Technical Design PackageEngineering Drawings Specifications Standards PerformanceQuality Assurance Reliability Data Modeling DataFeedback Addl part IDOperations SiteGlobal Mfg. NetworkCyber secure parts libraryFuture Operational CONOPS= Engineering Application Site= Operations Site Qualify parts/components Address AM challengesBuild AM capabilityEstablish process discipline No… Configuration control Part/material validation Process standardization Rigor or IT security Limited dedicated engineers/ operators Ensuring agility & flexibility for the warfighter; improving readiness & reducing cost B r e a k i n g B a r r i e r s … S i n c e 1 9 4 7 8
Centralized Applications Tomo rrow 9 Cyber secure library of AM TDP’s Design/ Innovation centers Identifying parts Designated engineers, designing, printing, and qualifying partsNon-critical, non-rotating, non-aero and aerospace componentsProduction centersCertified equipment, certified operators utilizing network approachB r e a k i n g B a r r i e r s … S i n c e 1 9 4 7
AMSIP lays out the foundation for safely establishing AM…moving slow to go fast Establish selective AM Capability: Depots & MAJCOM backshopsQualify Target parts: Tools, fixtures, prototypes, non-structural non-critical parts, structural non-aerospace parts Standard AM equipment, training, processes, and toolsReverse engineering process & toolsDevelop facility guidelines and post processingNOW TERM: Establishing AM Capability in Metals and PolymersExpand AM Capability: Additional weapon system components, expanding across Depots, MAJCOM’s, & SPO EngineeringQualify Target parts: Diminishing manufacturing, non-rotating, non-critical structural aircraft componentsDemonstrate network capability and cyber secure libraryValidate AM process controls, material characterization, process parameters, and reproducibilityNEAR TERM: Expanding AM Capability in Metals and PolymersTarget opportunities: Print anywhere on-demandTarget parts: Rotating and structural critical aircraftGlobal network of equipment and processesLONG TERM: Expanded AM NetworkAdditive Manufacturing Strategic Implementation PlanB r e a k i n g B a r r i e r s … S i n c e 1 9 4 710
MQ-9 Reaper Trailer Parts in Service (2016) AM Optimization B r e a k i n g B a r r i e r s … S i n c e 1 9 4 7
TF33 Engine StandParts in Service (2016) Bracket 17-4PH SS AM Optimization AFLCMC Packaging Engineering LabB r e a k i n g B a r r i e r s … S i n c e 1 9 4 7
Corrosion Impacts Safety of Flight and Airworthiness! Structural Integrity (ASIP) Avionics Integrity (AVIP) Mechanical Integrity (MECSIP)Propulsion Integrity (PSIP)Corrosion Prevention andControlB r e a k i n g B a r r i e r s … S i n c e 1 9 4 713
Inspections Maintenance W ashing R epai r s N on- A vailable Time Impact on Readiness and Availability Corrosion Negatively Impacts AvailabilityB r e a k i n g B a r r i e r s … S i n c e 1 9 4 714
B r e a k i n g B a r r i e r s … S i n c e 1 9 4 7 20 Cost of Corrosion Increases Weapon System Sustainment Preventative Corrosion Cost Inspect/ Test/ QA$957,065,103Treatment$880,529,019Clean/ Wash$605,382,694 Other$709,079,954$3,152,056,770AF FY15 Aerospace System MX Costs* 2016 AF CPC Report/ U.S. Air Force, 31 December 2016
21 Increasing Engineering Staff Increased staff from 5 to 20 engineers/specialists Corrosion/Field Mx SME Support Doubled engineers to boost SPO support Provide world-class aerospace corrosion expertise, guidance and training to maximize mission effectiveness, increase safety and reduce cost through improved materials and p rocessesTechnology Evaluation and IntegrationCorrosion Innovation Laboratory / Outdoor Test Site Coatings performance evaluationsTechnology maturation and implementationProcess GuidanceCorrosion Prevention Control Plans Corrosion Prevention Advisory BoardsTrainingAF Corrosion Prevention and Control Office Building a New Corrosion EnterpriseWhere Are We Going?B r e a k i n g B a r r i e r s … S i n c e 1 9 4 7
Non-Cr Coating Systems Transition non-chrome coating systems to USAF aircraft for OML applications New Technologies Get Ahead of Corrosion!HHL for corrosion removal Optimize washes based on environmental exposureUpdate wash cycle TOs and wash intervals based on actual corrosion exposure rates CBM+ for Corrosion PredictionWhere Are We Going?Robotic snake for corrosion detection B r e a k i n g B a r r i e r s … S i n c e 1 9 4 7
23 HHL for Support Equipment Approvals granted for use on support equipment Purchasing systems for field demonstration Next Steps: Field demonstrationsChecklist for installationOperation and trainingMonitoring and feedbackHHL for Aircraft Coating RemovalNumerous testing completedModifications completed for metallicsConducting last round of metallic tests Next Steps:Airworthiness CertificationComplete color recognition sensorComposite testingHHL for Small Area Paint and Corrosion Removal Initial focus on support equipment and vehicles• 300W and 1000W pulsed Nd: YAG lasers– 1064 nm wavelengthNext Steps:Four field units targeted for 2 year field demo starting in FY17:Kadena AB JAHickam AFB HITravis AFB CAPatrick AFB FLAFCPCO has hand held laserB r e a k i n g B a r r i e r s … S i n c e 1 9 4 7Hand Held Laser
- Increase mission readiness - Decrease m ain tenance costs- Provide significant cost savings and reduction in process flow time Replace current labor-intensive plastic media blast removal process Reduce damage potential from media blast process- Decrease labor intensivenature associated with NDI processes- Enable full aircraft inspectionand greatlyincreasethroughputcapacityReplace manual cleaning processes prior to painting - Provide significant cost savingsReduce process flow time- Provide significant costreductions in totsavings andal process times- Eliminatehazardous environment work26Robotic PaintRobotic Laser for Surface PrepRobotic NDIRobotic De-Paint Confined SpaceRobotic Corrosion InspectionRobotic ApplicationsB r e a k i n g B a r r i e r s … S i n c e 1 9 4 7
Qualifying nano- pulsed laser and CO 2 continuous wave laser Targeting B-2, F-22, F-35 Laser Surface Prep: Elimination of solvent cleaning and Pre-Kote surface treatmentExploring use of 300 W laser to clean substrate surface prior to top coat/paint applicationConducting prescreen tests to define parameters/gauge tech maturityCapability for a production-ready system for coating removal using either:1 kW nano-pulsed fiber laser20 kW CO2 continuous wave laserQualifying 1 kW nano- pulsed laser and CO2 continuous wave laserTargeting C-130, RQ-4 and C-17 CompositesLow Observable CoatingsFor Surface Adhesion20Kw and Co2 Nano Pulse Lasers Being QualifiedB r e a k i n g B a r r i e r s … S i n c e 1 9 4 727Large Area Robotic Stripping
Summary AFLCMC’s Approach - Big Rocks InitiativesRevolutionary Changes to Improve Mission Readiness Cost Effectiveness Asset Supportability Promotion of Enterprise MindsetEnterprise Impact!Ensuring Faster Implementation of Technology Across the EnterpriseB r e a k i n g B a r r i e r s … S i n c e 1 9 4 722
B r e a k i n g B a r r i e r s … S i n c e 1 9 4 7