HIGH EFFICIENCY FLIGHT LINE POWER, COOLING & DEHUMIDIFICATION (DH) FOR CORROSION CONTROL

This proposal is the result of an enterprise-wide collaboration of stakeholders in the development of corrosion mitigation techniques and equipment that integrate seamlessly into USAF flight lines. The objective of the system presented by Energy Quest is to provide deep dehumidification for aircraft to mitigate corrosion, avionics failures and improve aircraft availability without the creation of additional flight line equipment. Previous efforts provided support to the 18th MX, AFETS and Corrosion SMEs, as well as series of progressively improved systems based on the feedback of Corrosion and Avionics SMEs and input from aircraft maintainers and AGE personnel. A prototype system generated under SBIR topic AF112-219 was provided to the 18th MX Command at Kadena for an initial evaluation. Initial observations by the 18th MX, AFETS, E-3, KC-135 and F-15 at Kadena resulted in a unanimous conclusion that the dehumidification offered by this system would likely be effective at reducing corrosion and improve aircraft availability. Additionally, the prototype was observed to be of superior design and construction with improved corrosion resistance and maintainability.  The equipment performed the function of providing ground power and air conditioning across a broad range of aircraft that will reduce footprint and logistics trail by replacing multiple legacy systems. With an average consumption of 12.3 gallons/hour, the system also provides a 66% reduction in fuel use compared to the 36.6 gal/h consumed by the legacy -70 system.   In support of the 18th MX Command, the Corrosion Office, AFETS and SE&V, this proposal is for TCFI funding for the transition to production of the Energy Quest system. This proposal will also focus on progressing the Manufacturing Readiness Level (MRL) by maturing the methods, equipment, and personnel that will be used for the full production contract.  The lessons learned during Production Readiness phase will be used to improve design-for-manufacturability or modify the factory floor processes to achieve production time-to-build and cost targets, thus assuring a smooth and successful transition to Full Production phase.   Proposed cost for the Phase 3B Production Readiness program, presented herein, is $1,175,000. The Full Production phase will allow for the gradual ramp-up of production quantities and debugging of the manufacturing flow and operations, without adding risk to delivery of the remaining production schedule.  A Full Production phase annual build rate of 20, 30, 70, and 100 shipsets per year thereafter, is recommended under a Full Production contract.