aircraft structural integrity program asip briefing to loa conference 14 october 2008

1. Aircraft Structural Integrity Program (ASIP) Briefing to LOA Conference14 October 2008 Chuck Babish ASC/EN DSN: 785-5312 charles.babish@wpafb.af.mil

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3. 3 ASIP Process, Sustainment

4. 4 Structural Integrity Challenges Funding to execute ASIP as required Collection of usage data (flight data recorders) Analysis updates supported by durability testing Structural modifications NDI reliability Increasingly relied upon to protect safety Recently documented cases of missed cracks Structural health for an aging fleet Ability to translate above issues into quantified safety & economic risk Aging USAF fleets require disciplined ASIP execution to minimize unexpected field issues. Current resource constraints present a major challenge requiring high level attention. Air Force senior leadership need to take action to address ASIP execution shortfalls Aging USAF fleets require disciplined ASIP execution to minimize unexpected field issues. Current resource constraints present a major challenge requiring high level attention. Air Force senior leadership need to take action to address ASIP execution shortfalls

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6. 6 Back-Up Information

7. 7 Structural Integrity History Numerous fatigue failures on several aircraft in the 1950s Most notably, 4 B-47s in March through April 1958 ASIP established in Nov 1958 Low-time F-111 lost in Dec 1969 due to a pre-existing flaw ASIP modified to adopt damage tolerance in the early 1970s F-16 1st aircraft designed to be damage tolerant Numerous fatigue-related structural failures in the 1950’s resulted in the establishment of ASIP in 1958. A failure of a new F-111 due to a manufacturing defect resulted in the USAF adopting a damage tolerance policy as part of ASIP. Damage tolerant is the design philosophy of assuming a flaw is present on an aircraft from the time it is delivered without failure during its intended service life. The F-16 was the first AF system designed to be damage tolerant. Numerous fatigue-related structural failures in the 1950’s resulted in the establishment of ASIP in 1958. A failure of a new F-111 due to a manufacturing defect resulted in the USAF adopting a damage tolerance policy as part of ASIP. Damage tolerant is the design philosophy of assuming a flaw is present on an aircraft from the time it is delivered without failure during its intended service life. The F-16 was the first AF system designed to be damage tolerant.

8. 8 ASIP Phases

9. 9 ASIP Force Management, Key Tasks(Reference MIL-STD-1530C) Individual Aircraft Tracking (IAT) Requires minimum of 90% valid data capture rate for each aircraft to adjust maintenance intervals based on actual usage L/ESS Requires 20% valid data capture rate to update usage spectrum for service life analysis Structural maintenance records Detailed information on damage findings Force management updates Update life analysis to incorporate above results Recertification Potentially includes conducting additional full-scale durability test Aircraft are remaining in the USAF inventory for an unprecedented duration, far exceeding their design service life. The financial burden associated with maintaining the structural integrity of these systems for extended times continues to grow at a significant pace. Numerous systems require replacement of major aircraft components such as wings and other structural life extension programs to meet their revised retirement dates. Investments to maintain a viable ASIP on each program compete with requirements for enhanced operational capability and in many cases they are woefully under resourced Investments in operational data collection systems to adjust maintenance intervals based on actual usage, updates to structural models to improve predictive capabilities, tests and analyses to certify structural modifications to enable extended service lives are required to ensure continued airworthiness. A viable ASIP is essential to minimizing unanticipated structural issues. Recent structural issues on various aging USAF aircraft such as F-15 longerons, C-130 center wings, KC-135 engine struts and A-10 wings have increased Air Force senior management attention on ASIP execution in all systems. Aircraft are remaining in the USAF inventory for an unprecedented duration, far exceeding their design service life. The financial burden associated with maintaining the structural integrity of these systems for extended times continues to grow at a significant pace. Numerous systems require replacement of major aircraft components such as wings and other structural life extension programs to meet their revised retirement dates. Investments to maintain a viable ASIP on each program compete with requirements for enhanced operational capability and in many cases they are woefully under resourced Investments in operational data collection systems to adjust maintenance intervals based on actual usage, updates to structural models to improve predictive capabilities, tests and analyses to certify structural modifications to enable extended service lives are required to ensure continued airworthiness. A viable ASIP is essential to minimizing unanticipated structural issues. Recent structural issues on various aging USAF aircraft such as F-15 longerons, C-130 center wings, KC-135 engine struts and A-10 wings have increased Air Force senior management attention on ASIP execution in all systems.

10. 10 ASIP Review 2008 Summary ASIP is a robust engineering process that continues to protect structural integrity and safety ASIP execution issues identified USAF aircraft continue to age; structural health challenges exist and are expected to increase Usage severity and extended service life are cost drivers Approximately $8.8B investment required over the FYDP ($4.3B unfunded) to mitigate known structural challenges

11. 11 Scope of Aging A/C Challenge(Data as of Spring 2008)

12. 12 ASIP Review Team Conclusions with Logistics Impact Several systemic ASIP execution deficiencies identified Operational loads data (L/ESS) deficient on 17 MDS Actual usage severity data (IAT) deficient on 22 MDS Maintenance data collection improvements required for 17 MDS NDI is critical to ASIP execution and relied on for safety NDI capability baseline is required Skilled ALC NDI workforce is stressed/departing Aircraft are remaining in the USAF inventory for an unprecedented duration, far exceeding their design service life. The financial burden associated with maintaining the structural integrity of these systems for extended times continues to grow at a significant pace. Numerous systems require replacement of major aircraft components such as wings and other structural life extension programs to meet their revised retirement dates. Investments to maintain a viable ASIP on each program compete with requirements for enhanced operational capability and in many cases they are woefully under resourced Investments in operational data collection systems to adjust maintenance intervals based on actual usage, updates to structural models to improve predictive capabilities, tests and analyses to certify structural modifications to enable extended service lives are required to ensure continued airworthiness. A viable ASIP is essential to minimizing unanticipated structural issues. Recent structural issues on various aging USAF aircraft such as F-15 longerons, C-130 center wings, KC-135 engine struts and A-10 wings have increased Air Force senior management attention on ASIP execution in all systems. Aircraft are remaining in the USAF inventory for an unprecedented duration, far exceeding their design service life. The financial burden associated with maintaining the structural integrity of these systems for extended times continues to grow at a significant pace. Numerous systems require replacement of major aircraft components such as wings and other structural life extension programs to meet their revised retirement dates. Investments to maintain a viable ASIP on each program compete with requirements for enhanced operational capability and in many cases they are woefully under resourced Investments in operational data collection systems to adjust maintenance intervals based on actual usage, updates to structural models to improve predictive capabilities, tests and analyses to certify structural modifications to enable extended service lives are required to ensure continued airworthiness. A viable ASIP is essential to minimizing unanticipated structural issues. Recent structural issues on various aging USAF aircraft such as F-15 longerons, C-130 center wings, KC-135 engine struts and A-10 wings have increased Air Force senior management attention on ASIP execution in all systems.

13. 13 Summary ASIP is a robust engineering process that continues to protect structural integrity and safety USAF aircraft continue to age; structural health challenges exist and are expected to increase Need to continue to fund ASIP to manage aging aircraft risk and anticipate structural issues Usage data collection Predictive tools (models, tests, sensors, etc) Structural modifications to reduce maintenance burden (life cycle cost reductions) Aging USAF fleets require disciplined ASIP execution to minimize unexpected field issues. Current resource constraints present a major challenge requiring high level attention. Air Force senior leadership need to take action to address ASIP execution shortfalls Aging USAF fleets require disciplined ASIP execution to minimize unexpected field issues. Current resource constraints present a major challenge requiring high level attention. Air Force senior leadership need to take action to address ASIP execution shortfalls