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May 2010

UNCLASSIFIED. Presented to: NATO RESEARCH and Technology Organization (RTO) Applied Vehicle Technology (AVT) Pane l RTO- AVT -156. Design of Repairs for Battle Damaged Rotary Wing Aircraft.

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May 2010

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  1. UNCLASSIFIED Presented to: NATO RESEARCH and Technology Organization (RTO) Applied Vehicle Technology (AVT) Panel RTO- AVT -156 Design of Repairs for Battle Damaged Rotary Wing Aircraft Distribution authorized to DoD and DoD contractors only; Critical Technology; August 2001. Other requests for this document shall be referred to the U.S. Army RDECOM, ATTN: RDMR. Presented by: Mr. Kevin Rees Chief, Maintenance Engineering Division (MED) Aviation Engineering Directorate (AED) Aviation and Missile Research, Development and Engineering Center May 2010 UNCLASSIFIED

  2. Design of Repairs for Battle Damaged Rotary Wing Aircraft • Engineering Substantiation • Damage Evaluation • Logistics • Engineering Instructions • Engineering Calculations • Assistance • Fielding New Repair Technologies

  3. Design of Repairs for Battle Damaged Rotary Wing Aircraft • Engineering Substantiation • Original Strength • Impact to Other Systems • Hydraulics • Electrical • Weight & Balance • Aerodynamic Loading • Assistance

  4. Design of Repairs for Battle Damaged Rotary Wing Aircraft • Damage Evaluation • Inspection • Documentation • Projectiles • Entry • Multiple Exit / No Exit • Damage Nonlinear • Overstressed Parts • Paint Blistering • Sheared Fasteners • Thermal Damage • Discoloration • Conductivity

  5. Design of Repairs for Battle Damaged Rotary Wing Aircraft PROJECTILE DAMAGE ENTRY EXIT COLLATERAL

  6. Design of Repairs for Battle Damaged Rotary Wing Aircraft IMPACT DAMAGE CRACK

  7. Design of Repairs for Battle Damaged Rotary Wing Aircraft THERMAL DAMAGE

  8. Design of Repairs for Battle Damaged Rotary Wing Aircraft • Logistics • Personnel • Skill Level • Previous Experience • OEMFSR (Original Equipment Manufacture Field Service Representative) • On-sight Representative • Reports and Data • Materials and Equipment • Heat Treatment • Freezers • Machine Shop

  9. Design of Repairs for Battle Damaged Rotary Wing Aircraft • Engineering Instructions • Text • Non-Ambiguous • Logical • Legible • Attachments • Independent • Enhance Not Substitute

  10. Design of Repairs for Battle Damaged Rotary Wing Aircraft • Engineering Calculations • Stress • Loads • Beams • Torque Boxes • Axial Members • Shear Webs • Margin of Safety

  11. Design of Repairs for Battle Damaged Rotary Wing Aircraft Exhibit 1 – Unknown Loads

  12. Design of Repairs for Battle Damaged Rotary Wing Aircraft Exhibit 2 – Time Before Overhaul

  13. Design of Repairs for Battle Damaged Rotary Wing Aircraft Exhibit 3 - Review

  14. Design of Repairs for Battle Damaged Rotary Wing Aircraft Exhibit 3 - Review

  15. Design of Repairs for Battle Damaged Rotary Wing Aircraft Exhibit 3 - Review

  16. AH-64 Battle Damage Apache Tailboom BDAR, Damage

  17. AH-64 Battle Damage Repair 5 1 3 Repair Angle Skin Filler Remove damaged flange 2 6 4 Stringer Filler L-angle and spacer Skin Doubler

  18. Design of Repairs for Battle Damaged Rotary Wing Aircraft • Fielding New Repair Technologies • Qualification Plan • Materials & Processes • Analysis and Testing • Identify Logistic Requirements • Substantiation Report • Damage Limits • Calculations • Fastener and Material Selection – Worst Case • Additional Qualifications • Technicians and Equipment per Field Conditions • OEM Test Repair

  19. Design of Repairs for Battle Damaged Rotary Wing Aircraft • Conclusion • Engineer • Skilled in many areas • Determine Aircraft Loading • Airworthiness • Substantiation • Assistance • New Repairs • Substantiation

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