Advanced Non-Destructive Testing in Support of Life Cycle Management for Weapons System Components

The Air Force has a national defense-related mission need in the area of nondestructive testing (NDT) in support of Condition Based Maintenance (CBM) to maintain fleet readiness. In the current maintenance approach utilizing fixed, schedule-based requirements, more than 90% of wheels at Depot-level (D level) and Intermediate-level (I level) overhaul inspections are returned to service with no defects found, and yet failure of wheels on-wing persist. Additionally, Integrally Bladed Rotors (IBR’s), are expensive, difficult to maintain, and in high demand to supply the Next Generation Air Dominance (NGAD) fighter fleet of Air Force warfighters. Process Compensated Resonance Testing (PCRT) is a commercially implemented advanced NDT method that is uniquely able to support life cycle management and CBM. The primary objective of this program is to pilot PCRT programs for military landing gear and engine components across several military platforms including the wheels and brake components of the Boeing Stratofortress (B-52), and IBIR’s for the F-119 and F-135. To get the required data, Vibrant will install one or more production-grade PCRT fixtures to collect data on new, rejected, and/or repaired B-52 wheels, and will expand use on an already-deployed IBR PCRT fixture to collect data on additional engine components. PCRT inspections and CBM criteria will be configured based upon a statistical analysis of the data collected. As the programs are developed, the Vibrant Team comprised of representatives from Collins Aerospace, The Boeing Company, Pratt & Whitney, and Treble One will work to scope how an expanded PCRT with the integration of operational data from the weapons system, can contribute to true Condition Based Maintenance Plus (CBM+) programs. At the end of the program, testing recommendations how to track and test components, how to establish and plan the use of PCRT inspection criteria and operational feedback into successful CBM+ programs, and supporting data will be delivered to the Air Force. This project shall have a period of performance of 24 months with the not-to-exceed cost of $1,100,000.