Ruggedized, Lower Cost, Terahertz Specialty Coating Thickness Measurement System for Aircraft Depot and Field Sustainment

A prototype ruggedized, size, and cost-reduced “Next Generation Handheld THz Specialty Coating Thickness Measurement System for Aircraft Depot and Field Sustainment” will be designed, tested and delivered. The prototype will be evolved from TeraMetrix’s COTS light duty single point gauge (SPG) product. The Phase II deliverable will meet the following standards: MIL STD 180G drop test; MIL STD 810H dust intrusion; MIL STD339/1100 cable durability; IP64 Water Intrusion; and Class I Div. 2 certification for use around previously fueled aircraft. A signed supporting MOU from the F-22 Systems Program Office (AFLCMC/WWU) has been obtained. F-22 SPO and Depot has a national defense-related mission need to accurately measure the thickness of multilayer specialty coatings during in-service inspections; and during depot repair and refurbishment of these coatings. Fifth Generation aircraft, such as the F-22, have complex coating stacks that must be applied to exacting thickness tolerance to meet the performance specifications of the aircraft. Baseline technologies are limited in accuracy and precision, and a new and improved capability is required for higher quality aircraft sustainment with the lowest risk of costly rework. This is critical to ensure aircraft perform as expected to maximize survivability of the aircraft and pilot.