Collocate from the Air Force Research Laboratory. 25 March 2009 DM156467
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1 F-35 Corrosion Prevention and Control Programs Amanda Gentry F-35 Materials and Processes Collocate from the Air Force Research Laboratory 25 March 2009 DISTRIBUTION DISTRIBUTION STATEMENT STATEMENT A For A Unlimited For Unlimited Distribution Distribution (JSF 09-82) 1
2 Overview The F-35 Program where are we now? F-35 and Corrosion Prevention and Control Methodologies Accomplishments Thoughts on Maintenance Ongoing Areas of Research DISTRIBUTION STATEMENT A For Unlimited Distribution (JSF 09-82) 2
3 VISION DELIVER AND SUSTAIN THE MOST ADVANCED, AFFORDABLE STRIKE FIGHTER AIRCRAFT TO PROTECT FUTURE GENERATIONS WORLDWIDE. MISSION STATEMENT BE THE MODEL ACQUISITION PROGRAM FOR JOINT SERVICE AND INTERNATIONAL COOPERATION. DELIVER TO OUR WAR FIGHTERS AN AFFORDABLE AND EFFECTIVE NEXT GENERATION STRIKE FIGHTER WEAPON SYSTEM AND SUSTAIN IT WORLDWIDE. DM DISTRIBUTION STATEMENT A For Unlimited Distribution (JSF 09-82) 3
4 F-35 Family of Aircraft A family of affordable, multi-mission, strike fighter aircraft utilizing matured/demonstrated 21st century y technologies g Over 3000 planes to be built! STOVL CTOL CV DM DISTRIBUTION STATEMENT A For Unlimited Distribution (JSF 09-82) 4
5 F-35 Overview Joint Program U.S. Air Force, Navy, & Marine Corps International Partners United Kingdom, Italy, The Netherlands, Turkey, Canada, Australia, Denmark, Norway Security Cooperative Participants Israel, Singapore Joint Program Office Conventional Take-Off and Landing (CTOL) F- 35A Carrier Variant (CV) F-35C 3 Variants High Level el of Concurrency Design, Build, & Test all occurring simultaneously Short Take-Off and Vertical Land (STOVL) F-35B Primarily constructed from Aluminum, Titanium, and Composites DISTRIBUTION STATEMENT A For Unlimited Distribution (JSF 09-82) 5
6 International Supply Base United Kingdom Smith Industires Cytec Fiberite Honeywell/ Normalair Garrett LTD Italy Litton United Technologies Smiths Industries J.C. Carter Goodrich Aerospace Hq H.M. Dunn Sun Electric SP Aerospace The Netherlands Fokker Services Thales-NL Perot Systems Philips Fokker- Aerostructure Raytheon Systems Turkey Canada Denmark Norway Aselsan TAI Ayesas Milsoft Havelsan Teknoplazma DISTRIBUTION STATEMENT A For Unlimited Distribution (JSF 09-82) 6
7 F-35 Acquisition Timeline ASTOVL MRF ATA JAST JSF CDP IOC Dates USMC USAF USN NATF AX JSF SDD Derivatives and Enhancements 10/01 Award F-35 PRECURSOR PROGRAMS: Advanced Short Takeoff Vertical Landing Multi-Role Fighter Advanced Tactical Aircraft Naval Advanced Tactical Fighter Advanced Attack Joint Advanced Strike Technology Concept Definition Phase DM System Development and Demonstration LRIP 1-8 Low Rate Initial Production Full Rate Production Sustainment 2027 F-35 Passing Through The Eye Of The Needle 2033 DISTRIBUTION STATEMENT A For Unlimited Distribution (JSF 09-82) 7
8 Current Milestones (as of 13 March 09) AA-1 has over 100 flight test hours First F-35A to make First Flight in June 2009 First F-35B STOVL mode operations (Hover Pit) around March 2009 First F-35C to roll off assembly line around May aircraft currently in assembly or flight/ground test, including all of LRIP 1 aircraft and beginnings of LRIP2 By the end of 2009, all SDD aircraft are scheduled to be completed DISTRIBUTION STATEMENT A For Unlimited Distribution (JSF 09-82) 8
9 What will the F-35 Program look like in 5 Years (2014)? Producing 130 AC/Yr Supporting 210 Field Aircraft 20 AC in Operational Test 180 Students/Yr Thru ITC 5 USMC Squadrons in place Block 4.0 in Development DM Producing, Testing, Training, Deploying, Improving DISTRIBUTION STATEMENT A For Unlimited Distribution (JSF 09-82) 9
10 Affordable Manufacturing Potential Production Insertion Points year 300 LRIP FRP Post FRP Airc craft deliv veries per Major Tooling and Capital Expenditures D C E F Production F-35A/B/C Affordability Investment Notional F-35 Follow-on DM SDD A 12 B Production Deliveries Affordable Generation Of 1 Aircraft Per Day Through Reduce span time, touch labor, and improve process flow Reduce aircraft unit recurring flyaway (URF) and capital costs Supplier base development and supply chain stability DISTRIBUTION STATEMENT A For Unlimited Distribution (JSF 09-82) 10 35
11 F-35 and Corrosion Corrosion Prevention & Control Requirement The JSF Air System shall be durable, damage tolerant, fault tolerant, fatigue resistant, and corrosion resistant and be capable of being maintained and operated to meet the intended mission usage Requirement to use environmentally friendly materials and processes wherever possible, to include use of non-chromated primers Taken a cradle to grave approach: Design Considerations Methods for inspecting and restoring corrosion preventative features Maintenance and Repair methods when corrosion is discovered DISTRIBUTION STATEMENT A For Unlimited Distribution (JSF 09-82) 11
12 Corrosion Prevention/Control Philosophy Defined as the rigorous application of engineering design and analysis, quality assurance (QA), nondestructive inspection (NDI), manufacturing, operations and support technologies to prevent the initiation of corrosion, avoid functional impairment due to corrosion, and define processes for the tracking and repair of corrosion problems CPAB typically meets 1-2x per year to discuss progress Control o plans are considered ed evolutionary o and updated once per year with updated test results and allows for implementation of new technologies and procedures DISTRIBUTION STATEMENT A For Unlimited Distribution (JSF 09-82) 12
13 SDD Corrosion Prevention/Control Accomplishments Active minimization and mitigation of galvanic couples, especially aluminum, titanium, and composite matchups NDI Techniques/Procedures Extensive testing and qualification of nonchrome coatings Materials and systems on aircraft must pass a minimum of the ASTMG85 SO2/Salt Fog test (336 hours), even for CTOL! Actively incorporating lessons learned from legacy programs Cross attendance at CPAB s s, corrosion surveys AFRL/RX Collocated Engineers Informal discussions DISTRIBUTION STATEMENT A For Unlimited Distribution (JSF 09-82) 13
14 Thoughts on Maintenance Documentation ti and procedures in progress plans to incorporate maintainer perspective through workshops, schoolhouses Maintainers invited on regular basis to discuss with F35 staff and inspect planes Planes expected to follow service standard wash requirements Visual (mirrors/flashlights) and NDI/NDE used for inspections Standard NDI technologies supplemented by emerging tools for use on coatings and other features DISTRIBUTION STATEMENT A For Unlimited Distribution (JSF 09-82) 14
15 JSF Autonomic Logistics System Highly Supportable Aircraft Smart / Reliable Design Prognostics and Health Management Remove and Replace (R/R) Maintenance On Condition Maintenance Reduced Maintenance Skill Groups AFSC, MOS, etc. Training System Integrated Training Embedded Pilot Training On Demand Maintenance Training Air Vehicle Software Reuse Support System Sustaining Engineering g 24/7 Help Desk Electronic Joint-Service Tech Data Intelligent Maintenance Management Global Supply Chain Insight Support Equipment Management 22 Autonomic Logistics Information System Distributed Information System Enterprise Resource Solution Secure Scalable Deployable Autonomic Logistics Provides Order Of Magnitude O&S Savings DISTRIBUTION STATEMENT A For Unlimited Distribution (JSF 09-82) 15
16 Current Research Areas and Future Work NDI Technologies Chromium and Cadmium replacement technologies to have equivalent/better properties than current systems Corrosion Sensor Validation Corrosion testing of 100% production representative features including joints, structure, and OML stack-up Design approach validation Real world and laboratory exposures Evaluating pristine and damaged panels DISTRIBUTION STATEMENT A For Unlimited Distribution (JSF 09-82) 16
17 Summary F-35 is a program off the drawing board - Low Rate Production Lots already in assembly International Supply Chains and Joint Requirements add unique requirements to the program Corrosion prevention/control mindset was built into program from the beginning, and plans reviewed/updated regularly Evolutionary testing of improved materials and processes is ongoing and will continue well into the future DISTRIBUTION STATEMENT A For Unlimited Distribution (JSF 09-82) 17
18 Questions? Lockheed Martin Aeronautics Company DISTRIBUTION DISTRIBUTION DISTRIBUTION STATEMENT STATEMENT A.Approved A For A for Unlimited For public Unlimited release; Distribution distribution Distribution (JSF unlimited ) 18
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