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Problem Mg & Al Housings

Problem Mg & Al Housings. UH-60 Sump Corrosion sites. F-15 AMAD wear sites. F-16 ADG wear sites. Before. After. F-18 AMAD Mechanical Damage. F-16 Air Inlet wear sites. Before. After. Problem. Chafing - Aircraft Skin Panels & Hydro Tubes. Chafing Wear on Operational Panel.

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Problem Mg & Al Housings

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  1. ProblemMg & Al Housings UH-60 Sump Corrosion sites F-15 AMAD wear sites F-16 ADG wear sites Before After F-18 AMAD Mechanical Damage F-16 Air Inlet wear sites Before After

  2. Problem Chafing - Aircraft Skin Panels & Hydro Tubes Chafing Wear on Operational Panel Main Landing Gear Line Chafing Points Wear Tested Nose Landing Gear Accumulator Line 8 panels per aircraft Four panels per side Lt and Rt sides After

  3. BenefitsROI $2M $78M Total Annual Savings and ROI Including cost of CSRRT Program* $3,710,000 Return on Investment Ratio 11 *excluding hydro tube analysis

  4. ProblemUH-60 Sump - Magnesium Housing Corrosion sites ROI Unit Cost: $11K Annual Demand Rate: 85 Repair Cost: $880 Investment:$60K %ROI:16707% Annual Savings $860K Before After Repaired Sump

  5. Structural Prospective Part H53 Main GEARBOX Part Numbers 65391-11602-044 /65070-35542-045 Magnesium casting Cost New $313,800 5 housings repaired per year Shim Replacement Cold Spray will replace glued shims on bottom of mounting feet.

  6. Problem Hydraulic Tubing Chafing • ROI primarily based on lost flight hours and reduced maintenance manhours • Estimated at least1800 Mission Capable (MC) hours ~75 days improvement per year • Equates to $78M annually in lost training and maintenance costs* • * Based on AFIT Study, “Total Cost Comparison of B-1B Non-mission Capable (NMC) Drivers using Finite Source with Spares Queueing, Maj Dan Diehl, 2012 Chafing Points Wear Tested Spoiler Actuator line Nose Landing Gear Accumulator Line Main Landing Gear Line

  7. ProblemF-18 AMAD Gearbox ROI Unit Cost: $135K Annual Demand Rate: 4 Repair Cost: $2,500 Investment:$70K %ROI:9083% Annual Savings: $530K • The need to perform dimensional structural restoration of cast A357 aluminum components caused by damage, and the ability to repair structures in place. • Interior damage caused by gear spin-out repaired to dimensional tolerances, mechanical, thermal cycling & test stand test complete – savings $85K Gearbox Damaged Gearbox CS Repaired

  8. ProblemF-16 Air Inlet Housing Unit Cost: $1,857 Annual Cost: $46K Annual Demand Rate: 25 Repair Cost: $800 each Investment:$60K %ROI: 528% Annual Savings: $26K Repair sites ROI Nominated by AFMC Gen Wolfenbarger Staff Repaired Sump

  9. Chafing Wear on Operational Panel Problem B-1 Lt Upper Aft FEB Panel ROI Unit Cost: $225K Annual Demand Rate: 4 Repair Cost: $15K Investment: $50K %ROI: 5807% Annual Savings $840K Before After

  10. ProblemF-15 AMAD - Magnesium Housing Repair sites Nominated by AFMC Gen Wolfenbarger Staff Spares availability problem High Cost/High Demand ROI Unit Cost: $20K Annual Cost: $536K Annual Demand Rate: 26 Repair Cost: $2.5K each Investment:$70K %ROI: 8086% Annual Savings $472K Before After

  11. ProblemF-16 ADG- Magnesium Housing Repair sites Nominated by AFMC Gen Wolfenbarger Staff Spares availability problem High Cost/High Demand ROI Unit Cost: $50K Annual Cost: $330K Annual Demand Rate: 6.5 Repair Cost: $2K each Investment:$60K %ROI: 6337% Annual Savings $317K Before After Repaired Sump

  12. Problem B-1 FEB Panels - Total ROI B-1ROI DOD wide Avg Unit Cost: $135K $135K Annual Demand Rate: 96 768 Repair Cost: $10K $10K Investment: $70K $500K %ROI: 29055% 33689% Annual Savings: $1.7M $13.5M $840K After 8 panels per aircraft Four panels per side, Lt and Rt sides

  13. Cold Spray Applications B-1 Forward Equipment Bay B-1 Hydraulic Line Chafing Location – Cold Spray Pretreatment Integrally stiffened bonded panel – composite metal hybrid structure

  14. Fastener Holes – Before & After Damaged fastener hole Repaired Fastener OEM Fastener Hole

  15. Overview • Hydraulic lines were the #1 reason B-1s were grounded over the past year and continues today. 5,066 hours in 12 months. Also #1 manhour driver. • Chafing of hydraulic tubing is a similar chronic problem on nearly all DOD aircraft. • Solution - build up a metal wear surface on chafing areas with Cold Spray technology • Developmental and wear tests completed on B-1 over the last 2 years • Results demonstrated feasibility on 3 jets, 3 feedlines per jet • Estimated at least1800 MC hours (75 days) improvement per year (potentially much more) Deployed to Theater Chafing Points Wear Tested Spoiler Actuator line Nose Landing Gear Accumulator Line Main Landing Gear Line

  16. Cold Spray CP-Ti on Hydraulic Tubing Cold Spray Ti Titanium Tubing Interface Haynes AMS 4944 (Ti3Al42.5V) Hydraulic Tubing -.375” x .028”

  17. Expected Return on Investment • FEB Panel (ROI ~ 6 months) • Single panel savings = $225K • B-1B annual savings > $9.6M • Huge Potential savings if implemented AF wide • Investment at field level < $1M in equipment, training, & qualification • Anticipate ALC investment higher • Hydraulic Lines(ROI ~ 1 month ) • Primarily maintenance man-hour savings • B-1B >1800 Mission Capable hours (75 days) improvement per year (potentially much more) • Equates to $78M annually in lost training and maintenance costs*

  18. Fielded Application of Cold Spray Fielded SH-60 Seahawk with Cold Spray Mg Repair Operating Since August, 2009-Australian Navy ARL/JSF/DSTO Collaboration Three Fielded Blackhawk Medvac Units with Cold Spray Al Repair Operating Since August, 2009 ARL/AMCOM/Ft. Hood Collaboration BattleAxe-Eglin AFB-PM Matt MatyacBattleAxe will shower a large area with reactive fragments, devastating "soft" targets. (2006-2009) BattleAxe-Eglin AFB-PM Matt MatyacBattleAxe will shower a large area with reactive fragments, devastating "soft" targets. (2006-2009) B-1 Cold Spray Applications Preventative Maintenance of Hydro Lines – Ops since Sep ‘09 Forward Equipment Bay Panel – Ops since Jul ‘12 28 BW/ARL/OC-ALC/HF Webster/SDSM&T Collaboration Two Expeditionary Fighting Vehicles with Cold Spray Mg Repair Fielded Operating Since September, 2008 ARL/Allison Transmissions Collaboration • Power Transfer Module - PTM • - 10 Magnesium Castings • Transmission • - 13 Magnesium Castings

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