rcraft Structural Integrity gineering and NDT Case udies

Transcription

1 rcraft Structural Integrity gineering and NDT Case udies lum McGregor Principal Engineer October 2017

2 nda 1 QinetiQ Overview 2 Defence Regulatory Environment 3 ASI Program 4 Case Study 1 - F-18A/B LOTEX 5 Case Study 2 - PC-9/A ASIP Recovery 6 Case Study 3 - F/A-18A/B Bootstraps Wide Area Inspection 7 Summary

3 etiq Australia Overview netiq Australia is a people-based business providing trusted and impartial advice and services across the rospace, land and maritime domains of the Commonwealth Government of Australia Department of Defen d to Government, training and industry sectors rgely independent of the Defence supply chain and the large product-focused Original Equipment nufacturers. Impartiality combined with technical know-how. 0 people across Australia delaide elbourne (South Melbourne and DST-FB) anberra ydney risbane

4 etiq Australia Structural Integrity -year history of providing Structural Integrity Solutions to Defence ustry Partner to the Australian Defence Aviation Safety Authority in a tri-partite arrangement with DST: Regulatory Oversight Engineering Scientific Advice ategic alliance with DST Group for Research & Development livering services to DASA, DST, Sustainment Organisations, Acquisition Projects and Prime System egrators

5 SR Part 21J Approved Design Organisation ivileges cover all ADF registered aircraft for: lassification of changes and repairs pproval of minor repairs pproval of minor changes to Type Design DASR Part 21 Aircraft Design, Production & Certification DASR Part M Continuing Airworthiness Management DASR Part 145 Requirements for Maintenance Organisations

6 raft Structural Integrity Program - Overview I Assures structural strength and stiffness, throughout an aircraft s service life, when operated within the proved envelope, restrictions and limits F adopt the United States (MIL-STD-1530) Cradle to the Grave approach to ASI art 1 Design Information art 2 Design analysis and Development Testing art 3 Full Scale Testing art 4 Certification & In Service Management Data collation art 5 In Service Management

7 I Engineering and NDT Case Studies F/A-18A/B tructural Life Extension of RAAF /A-18A/B Hornet PC-9/A ASIP Recovery Project F-18A/B Bootstraps Wide Area Inspection

8 e Study 1 - F-18A/B LOTEX

9 e Study 1 - F-18A/B LOTEX - Approach ife Of Type Extension (as a minimum) needs to consider review of all baseline primary (FC/MC) airframe structure review of critical system and role equipment components review of all repairs and tail specific modifications to baseline primary airframe structure ocess for the review of all FC and MC Parts was: eview all available new data eassess the basis for SLL or SBI on Primary Airframe Structure xtend life limits where easy to do so ropose follow up actions where life management cannot be extended LOTEX achievable without further action LOTEX achievable with one-off inspection LOTEX achievable with recurring SBI program LOTEX achievable only with modification or replacement

10 e Study 1 - F-18A/B LOTEX - Approach LOTA Initial Scope Discuss Debate Agree Advise TFSPO Input & Feedback Develop Review Task Proposal for Major Structural Assembly Steering Group Committee (SGC) Consisting of experienced leaders from: DSTO ASI-DGTA QinetiQ Approved Approach Working Group Meeting Format More Work Required Actions Decisions

11 e Study 1 - F-18A/B LOTEX Inspection Summary 1 USN/RCAF 1 RAAF Gen. 0 NDT&CT 0 USN/RCAF 1 RAAF Gen. 0 NDT&CT 0 USN/RCAF 0 RAAF Gen. 2 NDT&CT 0 USN/RCAF 1 RAAF Gen. 2 NDT&CT 2 USN/RCAF 4 RAAF Gen. 5 NDT&CT 0 USN/RCAF 2 RAAF Gen. 0 NDT&CT USN/RCAF = Inspections sourced from USN HFH or RCAF ALEX inspections RAAF Gen = Inspections sourced from the RAAF General AAP NDT&CT = Inspections requiring NDT&CT Development 1 USN/RCAF 2 RAAF Gen. 3 NDT&CT DAVENG-DASA, LOTEX Brief to DD ASI, Feb 2017

12 e Study 2 - PC-9/A ASIP Recovery - Overview F lost confidence in management PC-9/A ASIP egradation, Condition Monitoring and atigue Management System (SCMS nd FMS)) omplex ICA ecommendations backlog onfiguration control ertification issues uccessive small extensions to PWD imiting the feasibility of large scale mprovements. Unclear structural inspection policy and gaps in fatigue certification Structur configura not accura capture Unable to assess effectiveness EDM program and establis emerging tren ASIP Recovery Project

13 e Study 2 - PC-9/A ASIP Recovery Fleet-wide Inspection et-wide audit to determine structural configuration of fatigue critical locations. pection layout based on consolidated ASIMP Volume 2. ample Findings on-standard repairs versus repair authorised by latest ICA / SBI policy top drilled cracks in SBI locations do not adhere to current repair policy o, new structural condition database VISION used to record all NDT reports, structural defects and Other nfiguration Records (OCRs).

14 e Study 2 - PC-9/A ASIP Recovery SBI Location Consolidation & ICA Revisio ample - Frame 9: BI to include all inspection locations and configurations ather than having four different SBI locations with arying thresholds and intervals hat require different NDT reports, etc. nsolidation improved clarity and efficiency the SBI program by educing the number of inspections and ationalising inspection intervals d to end audit of SBI ICA to identify deficiencies. vision of current ICA / SBI policy to: nsure all inspections included in NDT manual. implify implementation policy

15 e Study 2 - PC-9/A ASIP Recovery Outcomes Desktop audit of all Safety By Inspection (SBI) instructions for continued airworthiness (ICA) to identify FM deficiencies + Address fatigue certification recommendations backlog + Repackage Safety By Inspection (SBI) program and SBI Instructions for Continued Airworthiness (ICA)! Establish a robust and efficient ASIP Fleet-wide structural audit to establish structural configuration and inspect aft fuselage locations!! Revise ASIMP Vol2 and all supporting ICA: configuration, COMMERCIAL include IN CONFIDENCE fatigue management for nonbaseline configuration, outcomes from OLM program + SCMS Reinvigoration Project (TASPO) Review EDMP effectiveness and trend SCM data (routine ASIP task)

16 e Study 3 FA-18A/B Bootstraps Wide Area Inspection h instances of cracking detected within RAAF et AF accrual of aft fuselage buffet usage cation managed by limited Inspection and on ndition replacement e the inspections sufficient?

17 se Study 3 FA-18A/B Bootstraps Wide Area Inspection ootstrap Surface Finish Ion Vapour Deposit (IVD) Aluminium Coating Primer Thermal Foam, Adhesive & Sealant Numerous WHS complications to remove on a large scale ide Area Inspection Process Water picking sealant and foam removal Wide Area BHEC and SSEC Inspection Crack Indications excised for Forensic Examination Hot (80deg) Nitric Acid (50%) Etching Wide Area Close Visual Inspection Crack Indications excised for Forensic Examination ructural Integrity Implications still to be assessed S

18 mary craft Structural Integrity Program nsure the desired level of structural safety, performance, durability, and supportability with the least possible economic urden throughout the aircraft s service life -18A/B LOTEX chieved through combination of Engineering Analysis and Non Destructive Inspection -9/A ASIP Recovery egraded ASIP through reactive SBI Program development and continued proximity to PWD ecovery achieved though end to end audit of ICA, Fleet wide Inspection & SBI location consolidation otstraps Wide Area Inspection s the existing inspection program adequate?

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