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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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Problem mg al housings

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


Problem mg al housings

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


Problem mg al housings

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


Problem uh 60 sump magnesium housing

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


Structural prospective part

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.


Problem mg al housings

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


Problem f 18 amad gearbox

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


Problem f 16 air inlet housing

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


Problem mg al housings

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


Problem f 15 amad magnesium housing

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


Problem f 16 adg magnesium housing

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


Problem mg al housings

Problem

B-1 FEB Panels - Total

ROI B-1ROI DOD wide

Avg Unit Cost: $135K$135K

Annual Demand Rate: 96768

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


Problem mg al housings

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


Problem mg al housings

Fastener Holes – Before & After

Damaged fastener hole

Repaired Fastener

OEM Fastener Hole


Overview

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


Problem mg al housings

Cold Spray CP-Ti on Hydraulic Tubing

Cold Spray Ti

Titanium Tubing

Interface

Haynes AMS 4944 (Ti3Al42.5V) Hydraulic Tubing -.375” x .028”


Problem mg al housings

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*


Fielded application of cold spray

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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