Lowering F135 Integrally Bladed Rotor Sustainment Costs with SmartBlend

Blade Diagnostics Corporation (BDC) develops systems for measuring and analyzing the geometry and vibratory response of integrally bladed rotors (IBRs).á Their product, SmartBlend« Systems (SBS), incorporates next generation testing and analytics for active propulsion fleet maintenance.á SmartBlend uses specific information about each part to safely repair more IBRs and quickly return them to service, thus, reducing maintenance costs and improving fleet readiness. The SBS IBR data becomes part of a database which can be used to inform decision makers for improved workflow, repair strategies, and IBR asset management.á BDC worked with AFRL (Dayton) and ALC (Oklahoma City) to build and install a SmartBlend System for evaluating F119 IBRs at the ALC where it has been fully integrated into the F119 repair workflow.á Based on F119 damage rates it has been estimated that implementing SmartBlend technology for the F135 would provide an ROI of greater than 30 to 1.á The purpose of the proposed work is to compliment BDCs 19.2, X21.1, N22.1, and X23.4 SBIR projects by enhancing the F135 SmartBlend Core Measurement System (CMS) at OC-ALC to: (A) incorporate GMAP 3D scanning capability, (B) modify F135 stages 1 - 3á EAAU's for GMAP operation, (C) develop GMAP scan paths for F135 stages 1 - 3, and (D) Expand CMS excitation channels to 112 to fully utilize SmartBlend capability.á If BDC is awarded a Phase II, then ALC has committed to use the project deliverables to evaluate F135 stage 1 - 3 IBRs in the OC-ALCárepair depot.á Furthermore, the USAF/JPO will have SmartBlend CMS inspection capability for the entire F135 engine, regardless of future ECU enhancements.