Inherently Safe Automated Coating Removal Tool

Air Force on-aircraft coating and composite repair procedures of outer mold lines (OML) structures utilize a scarfing technique. Manually producing scarf geometries is untimely, imprecise, and can induce secondary damage to the surrounding structures and system components. Lengthy repairs, and secondary damage, significantly limit aircraft availability and increase sustainment costs. Therefore the Air Force seeks to develop a rapid, reliable coating repair process which reduces touch time, improves accuracy, and is inherently safe for use in on-aircraft (i.e. hazardous locations). Cornerstone Research Group Inc. (CRG) will develop a man-portable, automated coating removal tool using inherently safe removal methods and a motion control system with in-process OML metrology. Inherently safe removal methods mitigate the extent of engineering controls required to protect the operator, underlying composite substructure, and limit FOD migration from the repair site. During Phase I, CRG will define inherently safe coating removal methods and fabricate a prototype removal tool leveraging commercially available components. Lab demonstrations on surrogate structures will inform feasibility guiding Phase II refinement and operationally relevant OML repairs. Phase III will focus on tool certification and transition the technology to Air Force repair depots and commercialization of the on-aircraft, automated coating removal tool.