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I n t e g r i t y - S e r v i c e - E x c e l l e n c e Air Force Sustainment Center Industry Opportunities Enabling Cost Effective Readiness Mr. Kevin Stamey Director of Engineering Air Force Sustainment Center 1 Approved for Public Release: 72ABW-2016-0038

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I n t e g r i t y - S e r v i c e - E x c e l l e n c e

Air Force Sustainment Center

Industry Opportunities

Enabling

Cost

Effective Readiness

Mr. Kevin Stamey

Director of Engineering

Air Force Sustainment Center

1Approved for Public Release: 72ABW-2016-0038

Logistics & Sustainment Enterprise 2040

LSE 2040Vision & Roadmap for the Next 30 years

Attributes

1. 100% Data

Availability

2. 100% Parts

Availability

3. Environmentally

Compliant

4. Efficient Depot

5. Effective

Workforce

6. 100% Process

Control

7. Intelligent

Sustainment

Infrastructure

8. Resilient

Mission Ready

Software

Sustainment

9. Energy Efficacy

Achieving Art-of-the-Possible Through Out-of-the-Box Innovation

Multi-Domain Log C2Why We Need It

Log C2 processes & tools = enabled core capabilities = mission success3

1. USAF Core Logistics Capabilities, from AF Annex 4-0, Combat Support

AFSC VisionProblem Statement:The Air Force lacks the processes and

tools to conduct intelligent enterprise

Multi-Domain Logistics Command and

Control and maintain global visibility of

total logistics resources (materiel,

capabilities, and infrastructure),

resulting in the inability to effectively

and consistently set the theaters,

integrate with global and theater

planning, maintain visibility during full

spectrum operations, and reset forces.

The future AF enterprise needs: Combat Support components focused on Operations, Adaptive Basing, and the Warfighter

A Logistics Common Operating Picture (Log COP)/User-Defined Operating Picture (UDOP)

across air, space and cyber domains, providing timely, accurate information for Commanders

Full integration of Logistics into planning, current operations, and future operations

Command and Control of globally

integrated logistics synchronized

across air, space, and cyber

domains, conducted in collaboration

with theater C2, to achieve desired

effects across the spectrum of

conflict in highly contested and

denied environments while

optimizing allocation of resources

LSE 2040

Resilient, Mission Ready Software Sustainment

• Challenges

– Software Development Environments are targets for adversaries

• Systems and tools with unknown pedigrees provide adversaries

opportunities for shutting down software sustainment capability or

threaten weapon software operations

– Modern weapon system software needs to operate in an

interoperable battle-space with a diverse family of interrelated

systems

• Not tested early enough with high enough fidelity in relevant &

effective environment during sustainment phase

• Lack of fidelity during sustainment impacts warfighter requirements

validation/training techniques

• Results in higher costs and lesser quality software after fielding

• Need– Robust static and dynamic code analysis tools

– Trusted SDE tools

– High fidelity emulators of flight environment4

NDI Opportunities Abound

• NDI tools and process are 70-80 era

– Significant manual labor

– Very little automation or digital tools

– Heavily dependent on technician skill and data

interpretation; PoD varies

• NDI is a large driver of labor cost and depot flow

time

• Safety Critical: Must be accurate

– Improved PoD variance and crack size detection will

lengthen Mx Intervals

– Better tools & techniques to improve coverage

5End to End, Fully Integrated Digital NDI Capability

NDI Examples

• NDI Inspectors

overburdened with

paperwork

– Overly ripe for automation

– As much paperwork time as

actual inspecting

– Analog results

• Needs– Automated defect

identification

– Digitally recorded inspection

results

– Geo-registration

– Integrated with weapon

system data6

Technology Needs & Challenges

Coatings Removal• Current Coating Types

– Paint/Primer

– Cad Plating

– Etc.

• Current Removal Methods

– Chem-Strip

– Plastic Media Blast

– Water Jet

– Grinding

• Technology Needs/Challenges

– Need to Reduce Hazardous Waste Stream

– Effective/Efficient Removal Processes

– Minimization of Worker Exposure

– Zero damage to Aircraft/Part

– Waste Treatment7

Technology Needs & Challenges

Coatings and Masking• Replacement Needs/Challenges

– Eliminate coatings that contain HazMat

– Replacement for Brush Cd Plating

– Eliminate manual taping/masking

• Currently Masking Parts Prior to

Coating/Plating

– Mold Formed Rubber Masks

– Labor Intensive Tape Masks

– Wax Masks

• Technology Need - New Method of

Masking

– Robotic UV Cured Masking

– 3D Printed Rubber Maskings

– Brush Zn-Ni repair/touch up

8

Technology Needs/Challenges

Electro-Magnetic Testing

(EMP)

• Renewed strategic interest in EMP

– New Mil-Std-3023 High Altitude EMP

– New threats emerging

• Technology Need

– High Powered (1500 volts), Modular

Amplifier to drive load impedances

from short to open circuits for Direct

Drive testing

– Currently no COTS amplifier exists

• Previous vacuum tube technology

unsupportable

9

Technology Needs/Challenges

Condition Based Maintenance

(CBM) for Constant Speed

Drives (CSDs)• Wear of a CSD is a function of the number

of revolutions seen at the power input to

the CSD.

• Currently Requirement - “fly to fail” item

replacement strategy

– Wide range of failed conditions

– Un-necessary parts replacement

– Lifespan of each unit is not fulfilled

• Technology Need

– Effective method to determine revolutions

CSDs in support of CBM

10

Agile Manufacturing and Repair

• Sustainment Agility

– Obsolete part; “No-bids”

– Low demand, long lead time parts

• Additive Manufacturing/Repair

– Rapid and innovative solutions

– Reduced lead times for small qtys

• Digital Thread

– Digitized legacy data

– Reverse Engineering

11

Industrial Process Energy

• Industrial Energy Efficiency: Reduce IE consumed 5%

Y-O-Y, achieving NETZERO status by 2035

• Electricity

• Fossil Fuels

• Propane

• Energized Waters

• Gases

12

Misc Tech Needs

• Automated FOD Detection

• Tech data automation/visualization

– Projected tech data

– Google glass

– Video aids

– Light weight tablet digital tech data

• Automation of quality checking

– Sensing/verification of task completion

13

Innovation Centers

Vision

• Turnkey capability where govt, industry and

academia can be innovative and solve problems

– Tools and environment to foster innovation

• Space for creativity (think Google Campus)

• Engineering design tools (partnering with AFLCMC)

• Analysis tools

– Additive Manufacturing

• Rapid Rev Eng/Prototyping

• Advanced Repair Dev.

– Analyze/Test Designs

• Material and strength testing

14

DRIVEN BY

BYINNOVATION

DESIGN IT - MAKE IT - TRY IT - BREAK IT-REPEAT-RAPIDLY

Concept Description

• Desired capabilities:

– Polymer and metal additive manufacturing capability

– Testing and material characterization needed for part

qualification

– Post processing surface finishing

– Heat treating-preferably Hot Isostatic Press

• Business Model

– Cost sharing among “consortium” members

• Upfront investment and/or annual fees

• Govt Role

– Member and user

– Not the owner or operator of the Innovation Center

– Cooperative Research and Development Agreement

15Overarching Goal: Cost Effective Sustainment Agility

Questions?16

Backup slides for Newest Technology Needs

SBIR 17.1 Topics

17

Alternative Method of Surface Activation for Electroplating

High Strength Steel Landing Gear Parts

18

FULL DESCRIPTION:

The current blasting technique for activating surfaces prior to

plating utilizes either aluminum oxide or garnet

After the blasting the blast material is spent, and disposed of

as hazardous waste

OSHA citations have been received due to blasting processes

An alternative technology, such as Open Air Plasma (OAP),

would substantially reduce hazardous material waste

An alternate process such as OAP would only strip the first

few atom layers from the surface, compared to ten-thousandth

of an inch – potentially increasing part live

PROBLEM STATEMENT: Develop an alternative surface

activation technology for electroplating landing gear parts. The

technology shall reduce the amount of material removed from the

parts, improve plating adhesion, reduce waste, and lower risks to

both personnel & landing gear parts

TOPIC OBJECTIVE: Adhesion will be improved due to the

elimination of potential grit blast media. Also, less material will be

removed, increasing part lifespan

IMPACT IF APPROVED:

Reduce cost of overhaul of landing gear parts

Reduce disposal of hazardous waste

Increase worker safety

Decrease cost of landing gear maintenance

IMPACT IF NOT APPROVED:

Will not obtain the benefits of the listed impacts

Will continue to operate landing gear maintenance

operations ineffectively

TPOC NAME: Mr. David Astle and Mr. Dave Fredrick

ORGANIZATION: 417 SCMS/GUEA and 309th CMXG/ENL

NEED DATE:

STRATEGIC ALLIGNMENT: CoF Attributes

3) Environmentally Compliant

5) Effective Workforce

6) 100% Process Control

ENTERPRISE POTENTIAL: Multiple Landing gear / weapon

systems will be effected by this effort

DISTRIBUTION A. Approved for public release: distribution unlimited.

Electroplating 3D Printed Materials

19

PROBLEM STATEMENT: The metal plating of Fused Deposition

Modeling (FDM) parts is poorly defined with little information on

how to replicate the process. FDM parts plated with chromium,

nickel or copper can greatly enhance strength, durability, surface

hardness, and heat resistance

TOPIC OBJECTIVE: Research and develop an appropriate

process to include specifications, equipment requirements,

optimal applications and cost/benefit for metal plating 3D FDM

printed tooling.

TPOC NAME: Mr. Taylor Gittins

ORGANIZATION: MXDEZ

NEED DATE:

STRATEGIC ALLIGNMENT: CoF Attributes

2) 100% Pars Availability

4) Efficient Depot

6) 100% Process Control

ENTERPRISE POTENTIAL: This effort could impact any parts

made by FDM

FULL DESCRIPTION:

Calculated cost savings have not been accomplished due to

the maturity of the technology Expected saving from increased strength, durability and toughness of plated parts

FDM materials that may be metal plated are ASA, ABS-ESD7,

Nylon 12, Polycarbonate, or ULTEM 9085

Industry has claimed that the metal plating thickness of an

FDM part can be between 0.001 – 0.020 inches and can

improve strength by a factor of 20

The process for plating complex FDM printed parts is not well

understood from a design perspective

IMPACT IF APPROVED:

Enhance light weight FMD printed parts

Increase strength, durability and hardness of parts

Increase parts lifespan

Decrease MTBF

IMPACT IF NOT APPROVED:

Will not realize positive impacts

Slower modernization of depot maintenance

DISTRIBUTION A. Approved for public release: distribution unlimited.

Robotic Application of UV Cured

Maskants

20

FULL DESCRIPTION:

Part is placed in the machine, employee tells robot what part to

prep for plasma spray, the machine applies and cures the

maskant, and the mechanic removes the part from the

machine, prep blasts and applies plasma spray/HVOF/etc.

The technical need is not robotic application of maskant but the

ability for the robot to mask areas while applying maskant so

that no additional work is needed to prep the part for

processing.

PROBLEM STATEMENT:

The masking process for plasma spray may be greatly improved

with proper implementation to completely automate the process of

UV cured maskants.

TOPIC OBJECTIVE:

Robotic application of UV cured masking material that does not

require pre-masking to prevent maskant overspray. UV cured

masking material from Dymax has been demonstrated on new

and existing plasma workload. Some new workload would not

have been possible without the implementation of Dymax UV

cured maskants.

IMPACT IF APPROVED:

Could greatly improve plasma spray process by reducing part

prep time and creating consistent masking for parts

(reducing operator error).

IMPACT IF NOT APPROVED:

Maskant may be hand applied but hand application does not

eliminate operator error or reduce prep time.

TPOC NAME: Donna Stacy

ORGANIZATION: 76 MXSG

NEED DATE: 2019

STRATEGIC ALLIGNMENT: 4. Efficient Depot

ENTERPRISE POTENTIAL: Could potentially be utilized to

mask parts for plating, grit blast, paint, chemical strip, etc.

DISTRIBUTION A. Approved for public release: distribution unlimited.

Constant Speed Drive (CSD) Input Shaft

Counter

21

FULL DESCRIPTION: A method, or device, of counting the

number of input revolutions to the CSD is needed to correlate

use of the CSD to wear and then to establish maximum useful

life before overhaul.

PROBLEM STATEMENT: Wear (and usable life) of a CSD is a

function of the number of revolutions seen at the power input to

the CSD. However, information for hours on engine or wing is not

collected for the CSD. The CSD is managed under a “fly to fail”

item replacement strategy and CSD’s are returned to the depot in

a wide range of failed conditions, most of which accelerate

unnecessary parts replacement and overhaul work. A significant

number of units are returned long before the average return

period (Mean Time Between Demand) with unreliable reports for

why it was returned early.

TOPIC OBJECTIVE: An effective method is needed to determine

revolutions of Constant Speed Drives in support of Condition

Based Maintenance (CBM).

IMPACT IF APPROVED: Increased awareness of the actual

state of the CSD will allow better planning and more efficient

use of Depot resources and improved weapon system

availability.

IMPACT IF NOT APPROVED: Continued inefficient “fly to fail”

item replacement strategy for CDS resulting in unnecessary

parts replacement and overhaul work.

TPOC NAME: Gary Norman

ORGANIZATION: 422 SCMS

NEED DATE: Current Need

STRATEGIC ALLIGNMENT: Efficient Depot, 100% Parts

Availability

ENTERPRISE POTENTIAL: The resulting capability could

require enhancements for the production implementation

across military installations and the many potential

commercial applications in numerous industries to enhance

manufacturing and in-service quality control programs for

current and past production components.DISTRIBUTION A. Approved for public release: distribution unlimited.

Damage Tolerance Analysis of Grinding

Burn Cracks in High Strength Steels

22

FULL DESCRIPTION:

The AF wishes to better understand the fracture mechanics of

small cracks in burned HSS parts

The AF needs methods/models that can be used to manage

such cracks in LG

The AF needs to investigate the types of machining conditions

that encourage the formation of the mircro-cracks in burned

HSS

Burns in HSS LG parts commonly result in the condemnation

of the LG part

Burned LG parts have resulted in Class A Accidents

PROBLEM STATEMENT: Landing Gear (LG) are specialized

structures designed to sustain the high stresses and loads of

landing aircraft. Some LG parts are made of High Strength Steels

(HSS). During manufacture, rework, or chrome grinding there is

the potential that HSS LG parts are overheated resulting in an

under/over tempered martensitic condition (burn). A burn can

result in the formation of microstructurally and physically small

cracks in the 0.001 - 0.010 in. range

TOPIC OBJECTIVE: Develop special methods, data, or

applications for the modeling and crack growth analysis of

thermally induced cracks located in grinding burns of high

strength steel landing gear parts

IMPACT IF APPROVED:

Increased knowledge in the formation of cracks in burned

HSS

Increased safety of flight for HSS LG parts

Increased safety of future (LG and Weapon Systems)

designs that use HSS parts

Potential cost savings / avoidance

IMPACT IF NOT APPROVED:

Continue to operate HSS LG parts at an increased risk

Continue to operate at higher costs

Loss of improving future design that use HSS

TPOC NAME: Mr. Andrew Clark

ORGANIZATION: 417 SCMS/GUEA

NEED DATE:

STRATEGIC ALLIGNMENT: CoF Attributes:

3) 100% Data Integration & Availability

6) 100% Process Control

7) Intelligent Sustainment Network

ENTERPRISE POTENTIAL: Multiple Landing gear / weapon

systems will be effected by this effort

DISTRIBUTION A. Approved for public release: distribution unlimited.

Demonstration and Validation of Brush LHE Alkaline Zn-Ni

as a Brush Cadmium (Cd) Alternative

Brush Zn-Ni Plating

TECHNICAL APPROACHThe technical approach of this project is to first determine the

performance of the brush Cd plating alternatives, starting in a

controlled lab atmosphere and then moving into a full scale production

set up.

BENEFIT• Eliminate health exposure concerns of Cd plating and hex Cr

conversion coating at both the depot and in the field: thereby meeting

OSHA emission regulations, and complying with the requirements of

EO 13423

• Reduce environmental, safety, and health risk; reduced sustainment

costs resulting from decreased monitoring, haz-mat waste

management, personal protective equipment, and other cadmium

requirements.

PROJECT REQUIREMENT ($K)

MAJOR ACTIVITIES/MILESTONESPhase I:

• Months 1-4: Procure equipment & test assets

• Months 4-7: Plate Test Assets & Perform Quality Checks / Test

• Months 8-9: Evaluate Performance & Generate Final Report

Phase II:

• Months 1-4: Procure test assets, equipment & Dem/Val components

• Months 4-8: Determine chemistry variations & Eval post treatments

• Months 9-18: Plate Assets & Perform Qualification testing

• Months 18-20: Plate Dem/Val components

• Months 20-24: TDP Development & Engineering technical report

PROBLEM STATEMENTBrush Cd plating is used (along with post-chromate treatments) to

repair damaged Cd plating on aircraft parts that have exposed

substrate (i.e. low alloy steel) areas to provide a corrosion resistant

sacrificial coating. These bare areas are typically from in service

damage, or production areas exposed from rack plating points of

contact.. Frequently, Cd brush plating is applied to aircraft

components, fasteners and electrical connectors; however, Cd is a

known carcinogen and brush plating produces fuming which poses an

environmental and safety concern.

SOLUTIONThis effort will demonstrate/validate the use of LHE alkaline Zn-Ni

brush plating for touch up and/or plating repair on steel aircraft

components that were previously Cd or LHE alkaline Zn-Ni plated.

Description FY17 FY18 FY19 Total

Phase I – Feasibility $150 $150

Phase II – Dem / Val $500 $500 $1000

DISTRIBUTION A. Approved for public release: distribution unlimited.

F-16 Landing Gear Bushing Bore Repair

24

PROBLEM STATEMENT: The F-16 main landing gear (MLG)

and nose landing gear (NLG) connection points have wearable

bushings to transfer landing loads to the aircraft structure. Over

time these bushings wear and migrate out of the housing and

bulkhead bores. This may cause bushing bore to exceed tight out

of round limits and a need to oversize the bore. There are no

instructions on how to oversize the bore, nor adequate tooling for

the process

TOPIC OBJECTIVE: Develop tooling, procedures, training

materials, and drawings to repair all F-16 landing gear attachment

housing holes

TPOC NAME: Mr. Matt Fowers

ORGANIZATION: 309th AMXG/EN and AFLCMC/WWMEX (F-

16 Engineering)

NEED DATE:

STRATEGIC ALLIGNMENT: CoF Attributes

2) 100% Parts Availability

4) Efficient Depot

6) 100% Process Control

ENTERPRISE POTENTIAL: Landing gear bushing bore repair

could be used to fix F-16 weapon systems worldwide

IMPACT IF APPROVED:

Reduce TDY costs with fielded and on-site repairs

Reduce repair time by circumventing depot wait time

Increase MTBF on repaired assets

Increase aircraft availability

Provide precise and consistent results

IMPACT IF NOT APPROVED:

F-16 grounded for up to 6+ months until repair complete

No written procedures for current repair method

FULL DESCRIPTION:

Current repair method has damaged 341 bulkheads, resulting

in a replacement cost of ~$40,000 for material alone per unit

Estimated labor cost of $868K over 10 years

Damaged housing leads to increased downtime of F-16

Developed tooling and procedures must be designed to repair

the housing bores with the aircraft on jacks, with the landing

gear removed

Repair must be adaptable to both lightweight and heavyweight

configurations, which have slight differences in lug thickness

and bushing lengths

DISTRIBUTION A. Approved for public release: distribution unlimited.

Unique Modular, High Power, Cascadable Amplifier for

support of EMP Direct Drive Testing

25

FULL DESCRIPTION:

Current requirements for EMP survivability and hardness

assessment testing as defined in MIL-STD-3023, “High-

Altitude Electromagnetic Pulse (HEMP) Protection For Military

Aircraft” (21 November 2011) include Direct Drive techniques

in support of both Threat-level and Low Level Hardness

Maintenance/Hardness Surveillance.

Have spoken with representatives from Amplifier Research and

IFI about this issue and because of the small niche and the

large problem with possible damage and shutdown they are

not willing to invest in solution.

Existing Direct Drive Amplifier technology utilizes old vacuum

tube technology that is obsolete and very expensive to

maintain

PROBLEM STATEMENT:

Currently no existing Commercial-off-the-shelf product that will

support Amplifier requirements without shutdown or damage,

thereby leaving a shortfall in the ability to satisfy the requirements

of MIL-Standard 3023 and determine safety margins within

hardness/survivability of military tactical and strategic air vehicle

systems.

TOPIC OBJECTIVE:

Determine feasibility and develop concepts for a high power,

modular amplifier design to support wideband (10 kHz–2 GHz),

with minimum 10 kW Average Power, and capability to drive load

impedances from short to open circuits for Direct Drive testing.

IMPACT IF APPROVED:

Solid State solution would be able to verify safety margins on

individual mission critical systems throughout AF test articles

for compliance with Mil-STD 3023.

IMPACT IF NOT APPROVED:

Will have to fund a contractor for possible solution to

design/manufacture of Direct Drive system/amplifier.

TPOC NAME: Garland Anderson

ORGANIZATION: 559th SMXS/MXDPBA

NEED DATE: Jan 2018

STRATEGIC ALLIGNMENT: 4. Efficient Depot

ENTERPRISE POTENTIAL: Nuclear Hardness Maintenance

Hardness Surveillance Test capabilities set up at Hill and

Robins AFB, will need Direct Drive capabilities to facilitate

testing to Mil-Std 3023. Navy/Army would also benefit from

solution by replacing old, expensive to maintain amplifiers

and will test to new requirements in Mil-Std 3023.

DISTRIBUTION A. Approved for public release: distribution unlimited.

Development of Additive Manufacturing

for Landing Gear Components

26

FULL DESCRIPTION:

AM has the potential to improve LG designs

Other alloys (i.e. titanium) could improve part performance,

strength to weight ratio, weight, & corrosion resistance

USAF forecasting, planning, and procurement methods

require low quantity buys that eliminate economies of scale

An AM process could reduce the time to produce LG parts

from years to months

The AM process must be tested to provide the required data

to satisfy USAF airworthiness requirements

Design processes, metal powder combinations, manufacturing

& post processing techniques, qualification testing

requirement must be developed

PROBLEM STATEMENT: Due to the extreme operational loading

& harsh environments, Landing Gear (LG) designs have led to

manufacturing & fabrication processes that are lengthy &

expensive. Many LG components require forgings to ensure

proper grain flow to prevent fatigue failures. The forging process

adds significant costs, delays, & complexity to manufacturing LG.

Current machining methods limit LG component designs

TOPIC OBJECTIVE: Research and develop Additive

Manufacturing (AM) technologies for landing gear components to

enable testing and production of landing gear components using

AM techniques

IMPACT IF APPROVED:

Improved designs of LG parts

Improved designs will lead to safer LG part

Reduces weight of LG parts

LG parts availability will improve

Reduction in outside processing time

Improved production lead-time

Possible weight reduction

Optimized stress concentration areas

IMPACT IF NOT APPROVED:

The suboptimal process for replacing LG parts will remain

The use of non optimal LG designs will continue

TPOC NAME: Mr. Andrew Clark

ORGANIZATION: 417 SCMS/GUEA

NEED DATE:

STRATEGIC ALLIGNMENT: CoF Attributes

2 100% Parts Availability

4. Efficient Depot

6. 100% Process Control

ENTERPRISE POTENTIAL: Multiple Landing gear / weapon

systems will be effected by this effort

DISTRIBUTION A. Approved for public release: distribution unlimited.

Integrated 3-D Scan and Print

27

FULL DESCRIPTION:

The ideal situation would be a copy machine for three

dimensional objects. The object would be placed in a scanner

and a three dimensional “copy” would be produced with no

requirement for human interaction. The concept would be the

same as a paper copy machine, but the input and output

would be three dimensional objects. The output would not be

required to be detailed enough to distinguish components on a

circuit card. The main focus would be on any connectors and

that the exact size and shape was accurate so card guides

and holding fixtures could be fitted without the need for the

actual UUT.

PROBLEM STATEMENT:

Assets are difficult to obtain for TPS development, it is preferred

that we only have them in our possession for as little time as

possible. If the capability existed to create a three dimensional

model of the Asset in a short amount of time the Asset could be

“copied” and returned for use in the field until the Asset was

needed for integration.

TOPIC OBJECTIVE:

Provide the ability to link a three dimensional scanner through

software to a three dimensional printer to provide a closed system

capable of replicating form and fit of circuit card assemblies and

other avionics test hardware components with no human

interaction.

IMPACT IF APPROVED:

Development time for ITAs and TPSs would be decreased if

they were not dependent on UUT availability.

IMPACT IF NOT APPROVED:

TPS development times will continue to be affected by UUT

availability.

TPOC NAME: Simon Wayne / Scott Moody

ORGANIZATION: USAF AFMC 556 SMXS/MXDPB

NEED DATE: Est. CY2020

STRATEGIC ALLIGNMENT: N/A

ENTERPRISE POTENTIAL: Could be used in any shop on

base or in the AF that requires/uses additive manufacturing.

DISTRIBUTION A. Approved for public release: distribution unlimited.

Hardware Modeler Replacement for Digital

Device Simulation

28

FULL DESCRIPTION:

Many custom and hybrid ICs and custom electronic

components cannot be modeled in simulation software

because of their complexity and lack of technical data.

Location of the components within the SRU topology can also

prevent reverse engineering. The current hardware modeler in

conjunction with the Teradyne LASAR digital simulator has the

ability to perform this modeling. It is also able to retain input

and output patterns for entire clock cycles, and reestablish the

state of the device. The simulation results are available for

use in further simulations of the SRU. The current Air Force

family of testers, the VDATS, is equipped with Teradyne digital

test instruments that work in conjunction with the LASAR

simulator output to produce fault dictionary and guided probe

diagnostics for the VDATS test station. These diagnostics

indicate repair actions to be taken by technicians to return

defective SRUs to serviceable condition.

PROBLEM STATEMENT:

The D300 hardware modeler supports development and

maintenance of test programs used to test and indicate

repair actions for avionic circuit card assemblies. The

current hardware modeler is obsolete and no longer

supported. Current units are being used for parts to maintain

the viability of the system.

TOPIC OBJECTIVE:

Investigate the use of the VDATS Di-Series digital

subsystem (or equivalent) as a replacement for the D300

hardware modeler.

IMPACT IF APPROVED: Support for maintenance and

development of TPSs for SRUs containing components that

must be modeled is extended, and cost of reverse

engineering or loss of functional test is avoided.

IMPACT IF NOT APPROVED: Potential loss of avionics test

and repair for SRUs that depend on hardware modeling.

TPOC NAME: John Payne

ORGANIZATION: USAF AFMC 556 SMXS/MXDPA

NEED DATE: Est. CY2020

STRATEGIC ALLIGNMENT: N/A

ENTERPRISE POTENTIAL: Multiple weapon system avionic

repairs at all three ALCs are supported by TPSs that utilize

the legacy hardware modeler. LASAR and Teradyne DTIs

are used by other DoD agencies and industry.

DISTRIBUTION A. Approved for public release: distribution unlimited.