Crosthwaite G and McClure J 27 Nov 2012 F 22 ASIP Roadshow Benefits On Overall ASIP Execution 2012 Aircraft Structural Integrity Program Conferenc

F-22 System Program Office
Birthplace, Home & Future of Aerospace
F-22 ASIP Roadshow: Benefits on overall ASIP Execution DEC 2012

George Crosthwaite & John McClure AFLCMC/WWUE
Distribution Statement A: Approved for public release; distribution is unlimited 12/3/2012
Background
Started in 2008 due to field communication issues, and to track down reasons for missing data Currently there are 7 AFBs operating the F-22
Scattered among several MAJCOMs: ACC, PACAF, AETC, AFFTC and ANG Visit 1 per quarter
Format
Brief OG and MXG commanders on usage and overarching topics Meet with AMUs and FSs to discuss issues on the unit level Meet with the LO shop to go over any coatings issues and stripping techniques Meet with the NDI shop to discover any complications with tools or procedures Meet with ACC representatives to cover not only base issues but the fleet as a whole*
*Only occurs at ACC HQ base
Purpose
Present current usage and discuss ways to alleviate severity Make sure commanders are knowledgeable about who we are and what we do
Rotate ~ every 2 years
Provide communication channels for any future problems Alert field of any upcoming/ongoing issues, find out any issues the field is experiencing unbeknownst to the SPO
Data
Achieving 90+% fleet average on data download rates

Back in 2008 the worst jet download rate was 65% In just 4 years that jet is still the worst but now over 80%
100.00 95.00 90.00 85.00 80.00 Hours Sortie Time 75.00 Sortie Time Received 70.00 65.00 Percent
60.00
55.00 50.00 Aircraft
Integrity Data Collection Trend

100% 90% 80%
ASIP Road Shows Begin
Integrity Data Caputre Rate
70% 60% 50% 40% 30% 20%
Data Capture Rate Required Capture Rate
July 2004
Dec 2009
July 2008
10% 0% 0 1
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
Dec 2006
IAT Report Number

Sep 2012
Usage
Represents fatigue critical structure Correlates well to wing loads and NzW (primary fatigue driver)
Control Point CPH-0014A FS610 Bulkhead LHS Lower Wing Attach Lug
Usage
1400 1200
More
Equivalent Flight Hours
1000
800
600
400
Less Severe
Training Non-
0 200 400 600 800 1000 1200 1400
200
Actual Flight Hours

Usage Trends
Compare quarterly and current year trends
Engine Usage
Not affiliated with ASIP Organized visits already in place Engine SPO can relay the timeline for major engine maintenance based on current usage
Increased Usage
10
Rotation
Aircraft Fatigue Severity Ranking

Semi-annual Base Specific
Allows Rotation of Severe Missions
All Usage through June 2012 Severity Ratio 1.27 1.22 1.19 1.15 1.02 1.05 1.04 1.00 1.01 0.97 1.00 1.00 1.00 1.00 0.92 0.94 0.93 0.93 0.89 0.85 0.76 0.76 0.72 0.71 0.65
2nd Quarter 2012 Severity Ratio 1.56 0.87 1.50 1.64 1.22 1.12 1.12 1.02 0.82 0.97 0.69 1.04 0.93 0.64 1.21 0.76 0.89 0.66 0.63 0.80 1.18 0.68 0.55 1.33 0.89
1st Quarter 2012
EFH 933 1011 746 880 1258 1023 856 1142 1028 1172 935 785 729 488 958 724 646 486 652 628 713 435 606 431 510
AFH 735 829 627 765 1233 974 823 1142 1018 1203 935 785 729 488 1038 772 691 523 732 740 937 573 847 604 784
AFH 62 52 48 55 37 45 47 32 56 89 47 41 42 25 41 56 52 48 38 54 63 18 48 53 42
AFH 50 10 56 45 46 71 46 64 33 34 22 56 55 33 48 40 39 49 45 39 53 94 56 47 79
Data is for illustration not actual values
Time Remaining to Reach Severity 8000 EFH at Current Ratio Avg. Rate 3.50 5366 0.90 5546 0.74 5977 0.72 6077 0.70 6585 1.25 6596 0.76 6836 0.71 6858 0.54 6893 0.74 7036 0.84 7065 1.03 7215 0.88 7271 1.21 7512 0.37 7709 0.37 7810 1.17 7917 0.56 8122 0.51 8325 1.00 8803 0.79 9795 0.77 10093 0.45 10583 0.60 10776 0.43 11779
11
Weight Reduction
Reducing weight by removing stores to minimum requirements

4% life savings, which works out to ~2 more years of service
Saving high G maneuvers until later in flight

Lower fuel weight
12
Flight Procedures
Distance to range restrictions

Range is close to base, less chance to burn fuel weight before maneuvering
G warm-up maneuvers
Accounts for 10% of all high Nz events Recommended performing at higher altitude to lower wing loads
13
Flight Procedures
Syllabus
Mission types that are more severe are generally higher priority
11 mission profiles Air-to-air training the most severe and highest priority
Jet availability
Less Ao the more focus on BFM Scheduling with depot inductions and overfly requests around PMPs
14
Tank Carriage
External Tank Usage

30%
25% Total Tank Usage 20% TO Base = Landing Base 15%
10%
5%
0% Fleet Base A Base B Base C Base D Base E Base F
External fuel tank usage was exceeding the anticipated 10%

Bases stated their lack of flying with tanks Restructured calculation of base usage to exclude Ferry Flights
15
Software
Software update added an ICAW from Over-G monitoring that was not in previous OFPs
Field started seeing ICAWs, mostly during demo flights, and was unaware of the cause
Further update resulted in a nuisance OverG Hard Landing ICAW that asserted on startup
Happened randomly and only on some jets
Meeting with the field/pilots allowed us to address the changes in the flight software so they were aware and could alter their planning accordingly
16
Corrosion
Ongoing problem with F-22

Corrosion on the cockpit floor being the most recent find Make sure they are pro-actively looking for and preventing corrosion
17
Coating Issues
Keeping them on the lookout
18
Tooling
Provide MX community with new tools to demo shortly after they make the approved list
EVC Quick Skive Pneumatic Removal Tool Pneumatic Pencil Grinder
19
NDI
Ultrasonic inspections were shut off to protect aircraft safety

TOD was generically created and for old UT systems Ensure that bases were submitting an AR to get proper procedures AR database can be accessed to match inspections without submitting new request
Tasks currently being reworked

Provide the NDI personnel at the base the burndown schedule of the rework
20
SPO Benefit
Better physical understanding of the jet
21
Summary
Link Operations with Usage Tracking Data Identification of Maintainer Issues

TO Clarification NDI Readiness Aircraft Downtime Drivers Emerging Repair Issues Data Collection Challenges/Procedures
22
Conclusions
Necessary to have direct contact with the field to keep communication lines open Warfighter Understands Impact of Flying Profiles and Usage Variation Has on Service Life Identify and Mitigate Emerging Maintenance Issues to Optimize Aircraft Availability
Communication is the key to successfully sustaining any product for the warfighter
23
Acknowledgements
Lockheed Martin
Suresh Patel Pete Caruso
Engine SPO
Gary Burns Mike Duffy
SSO
Dave Nielson
24
Questions?
25

Crosthwaite G and McClure J 27 Nov 2012 F 22 ASIP Roadshow Benefits On Overall ASIP Execution 2012 Aircraft Structural Integrity Program Conferenc

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Crosthwaite G and McClure J 27 Nov 2012 F 22 ASIP Roadshow Benefits On Overall ASIP Execution 2012 Aircraft Structural Integrity Program Conferenc

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F-22 System Program Office

Birthplace, Home & Future of Aerospace

F-22 ASIP Roadshow: Benefits on overall ASIP Execution DEC 2012

Distribution Statement A: Approved for public release; distribution is unlimited 12/3/2012

Distribution Statement A: Approved for public release; distribution is unlimited 12/3/2012

Achieving 90+% fleet average on data download rates

Distribution Statement A: Approved for public release; distribution is unlimited 12/3/2012

Integrity Data Collection Trend

ASIP Road Shows Begin

Integrity Data Caputre Rate

70% 60% 50% 40% 30% 20%

Data Capture Rate Required Capture Rate

IAT Report Number

Distribution Statement A: Approved for public release; distribution is unlimited 12/3/2012

Equivalent Flight Hours

Actual Flight Hours

Compare quarterly and current year trends

Distribution Statement A: Approved for public release; distribution is unlimited 12/3/2012

Distribution Statement A: Approved for public release; distribution is unlimited 12/3/2012

Aircraft Fatigue Severity Ranking

1st Quarter 2012

Data is for illustration not actual values

Distribution Statement A: Approved for public release; distribution is unlimited 12/3/2012

Reducing weight by removing stores to minimum requirements

Saving high G maneuvers until later in flight

Distribution Statement A: Approved for public release; distribution is unlimited 12/3/2012

Distance to range restrictions

Distribution Statement A: Approved for public release; distribution is unlimited 12/3/2012

Distribution Statement A: Approved for public release; distribution is unlimited 12/3/2012

External Tank Usage

25% Total Tank Usage 20% TO Base = Landing Base 15%

0% Fleet Base A Base B Base C Base D Base E Base F

External fuel tank usage was exceeding the anticipated 10%

Ongoing problem with F-22

Distribution Statement A: Approved for public release; distribution is unlimited 12/3/2012

Keeping them on the lookout

Distribution Statement A: Approved for public release; distribution is unlimited 12/3/2012

Distribution Statement A: Approved for public release; distribution is unlimited 12/3/2012

Ultrasonic inspections were shut off to protect aircraft safety

Tasks currently being reworked

Better physical understanding of the jet

Distribution Statement A: Approved for public release; distribution is unlimited 12/3/2012

Link Operations with Usage Tracking Data Identification of Maintainer Issues

Distribution Statement A: Approved for public release; distribution is unlimited 12/3/2012

Distribution Statement A: Approved for public release; distribution is unlimited 12/3/2012

Distribution Statement A: Approved for public release; distribution is unlimited 12/3/2012

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