F-15 WING SPAR INSPECTION

Notice Date

March 5, 2001

Contracting Office

Sandia National Laboratories, Technology Partnerships Dept., PO Box 5800-MS1380, Albuquerque, NM 87185-1380

ZIP Code

87185-1380

E-Mail Address

Alane Dulski (adulsk@sandia.gov)

Description

PROJECT: The Department of the Air Force is interested in developing a new nondestructive inspection (NDI) process for detecting 2nd layer fatigue cracks in F-15 wing spars. This project is being conducted in two phases. The first phase will include a survey of technologies to identify potential project participants. During this phase a feasibility study will be conducted to assess existing system capabilities or the ability of a participant to develop this capability. The second phase will include laboratory validation testing and on-aircraft functional testing, an acceptance test, a Probability of Detection (POD) reliability study and the development of formal inspection procedures. The objective of the inspection is to perform a 2nd layer inspection around the taperlock fastener holes of the F-15 lower wing spar flange from the exterior or underside of the wing skin. These fasteners are made from various materials including Titanium and Stainless Steel and vary in size from 3/16 to 7/16 inches in diameter. The lower skin is Titanium and is .190 inches thick. The cap of the lower wing spars to be inspected is also Titanium. The spar cap is tapered and can range in thickness from .19 to .5 inches thick depending on the location on the spar and aircraft model. The inspection is compounded by a .060 inch deep sealant groove in the faying surface of the spar cap. This grove runs lengthwise with the spar and varies in width from .530 to.630 inches. Many of the fasteners to be inspected are located in the sealant groove. There are approximately 200 spar fasteners per wing associated with this inspection need. Initial efforts should focus on detection of < 0.050 inch second layer fatigue cracks that initiate in the spar fastener holes. A follow-on objective to this effort could include an inspection of the upper wing spar flange through Aluminum skin and the inspection of additional wing spars that are made of Aluminum. Potential candidates will be asked to provide a formal response describing their technical approach. Additional information on the content of the formal response will be provided. Responses will be reviewed by the Airworthiness Assurance NDI Validation Center (AANC) at Sandia National Laboratories in Albuquerque, NM. The AANC will summarize the responses and make recommendations to the Air Force. SCHEDULE: Potential participants will be surveyed in March -- May 2001. Test specimens will be available for potential participants to use for feasibility testing during the period of May -- September 2001. Formal responses from interested participants will be required by the end of September 2001. A decision on system selection and on the implementation of Phase 2 will be made by the end of December 2001. Phase 2, if implemented, will take place during 2002. REQUESTS FOR INFORMATION OR PARTICIPATION: Vendors interested in being considered for this program should contact Mike Ashbaugh or Gerald Langwell at (505) 843-8722 before April 1. SYSTEM PROCUREMENT: A prototype system may be procured as a part of Phase 2. Any additional system procurement will be conducted by the USAF. Participation in this project does not guarantee that the USAF will procure any systems. Participants in the Phase 1 feasibility study will not be reimbursed for any costs incurred. <

Record

Loren Data Corp. 20010307/SPMSC011.HTM (W-064 SN50F2F2)