Manufacture of NSN 2840-0038-64656 Thermocouple Cover for Pratt & Whitney TF33

Diminishing manufacturing source problems continue to cause shortages for critical DoD weapons systems, negatively impacting readiness. Subcomponents become obsolete and manufacturers stop supporting parts, and it becomes difficult for the government to acquire approved parts at a fair or reasonable price — or at any price.This scenario is the case for NSN 2840-0038-64656, the thermocouple cover for the diffuser section of the Pratt & Whitney TF33 turbofan engine, pictured here. Before this part was used on the TF33, it was used on the J57 turbojet engine. Both engines have been used on well-known aircraft such as the B-52 Stratofortress and the C-135 Stratolifter. The non-availability of the thermocouple cover appears to be driven by the original manufacturing method for the part: forging. Forging is an expensive and time consuming process, requiring dies and long lead times. To maintain profitability for such a part, manufacturers would need to maintain a high order volume which no longer exists. TAF will permanently resolve this issue as a new source by producing the part at equivalent or higher performing specifications with updated manufacturing processes that do not require such high operating costs and are consistent with the Pratt & Whitney drawing and requirements for the part.