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Dimensional Restoration of Aircraft Components Damaged by Corrosion

Description:

OBJECTIVE: To resolve issues with aircraft components damaged by corrosion in hidden and/or hard to access locations by providing a capability for on-site dimensional restoration of damage awhile providing improved corrosion protection. DESCRIPTION: Current methods for restoration of corrosion affected aircraft components in the Air Logistics Complex (ALC) are in need of process improvement and equipment enhancement. In order to align with high velocity maintenance (HVM) procedures in use in the ALCs, the improved methods for restoration must be capable of relatively quick removal of corrosion products and dimensional restoration of substrates and be applicable to complex geometries and internal bores. Preferred methods will also require no surface finishing after dimensional restoration and will provide precise control over thickness of applied repair material. Also required are environmentally friendly methods of restoration that do not require use of hazardous materials and generation and disposal of hazardous wastes, such as chromate containing primers and coatings. Eliminating hazardous waste will significantly reduce cost of corrosion repair. Current methods for restoration of corrosion affected aircraft components in the Air Logistics Complex (ALC) are in need of process improvement and equipment enhancement. In order to align with high velocity maintenance (HVM) procedures in use in the ALCs, the improved methods for restoration must be capable of relatively quick removal of corrosion products and provide dimensional restoration of substrates that are applicable to complex geometries and internal bores. Preferred methods will also require no surface finishing after dimensional restoration and will provide precise control over thickness of applied repair material. Also required are environmentally friendly methods of restoration that do not require use of hazardous materials and generation and disposal of hazardous wastes, such as chromate containing primers and coatings. Eliminating hazardous waste will significantly reduce cost of corrosion repair. Portability of the method/equipment will facilitate on-site repairs. There has been a considerable body of research leading to innovations in equipment and repair processes which can lead to solutions for the issues with the process of dimensional restoration on complex aircraft component surfaces. Use of commercial of the shelf (COTS) equipment and methods, especially those approved for use in related applications, can provide significant efficiency and cost savings to the Air Force, without delays attending extensive R & D and testing. Portability of the method/equipment will facilitate on-site repairs. There has been a considerable body of research leading to innovations in equipment and repair processes which can lead to solutions for the issues with the process of dimensional restoration on complex aircraft component surfaces. Use of commercial of the shelf (COTS) equipment and methods, especially those approved for use in related applications, can provide significant efficiency and cost savings to the Air Force, without delays attending extensive R & D and testing. PHASE I: Perform research to identify and characterize components, areas requiring dimensional restoration, material types, damage areas and requirements for restoration (shape, size, thickness, and design to correct or limit corrosion). Provide a concept demonstration of the technical approach and methodology to determine feasibility of prescribed applications. PHASE II: Based on the technologies and methods identified in Phase One and presented during the concept demonstration, develop a streamlined solution for dimensional restoration to be used across Air Force Material Command (AFMC) depots. Demonstrate the solution(s) in a real-world environment and obtain MIL-SPEC approval for use of the process in the ALC depots and possible transition into commercialization applications. PHASE III: Response to this solicitation can be used in dimensional restoration efforts throughout the defense industrial base (DIB), and within the commercial and general aviation community. REFERENCES: 1. Aircraft Cleaning and Corrosion Control - http://www.faa.gov/library/manuals/aircraft/amt_handbook/media/faa-8083-30_ch06.pdf 2. Air Force Corrosion Prevention and Control Program - https://www.corrdefense.org/Academia%20Government%20and%20Industry/SERVICE%20OVERVIEWS%20-%20BULLOCK%20-%20%20AFCPCO%20Tri-Service%20Conf%20paper.pdf 3. Air Force Corrosion Prevention and Control Office - http://www.asetsdefense.org/documents/Workshops/SURF-FIN-TempeAZ-02-08/Briefings/Doak-AF_Corr_Prev_ & _Ctrl.pdf http://afcpo.com/
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