DoD Maintenance Innovation Challenge (MIC) Finalists 2023
JTEG Forum Minutes
Event: On 30 January 2024, the Joint Technology Exchange Group (JTEG) hosted a virtual technology forum that featured the “DoD Maintenance Innovation Challenge (MIC) Finalists”.
Purpose: The purpose of this forum was to provide an opportunity for the 2023 MIC finalists to present their capabilities to the JTEG audience. In November 2023, six finalists were selected from 89 MIC submissions and the finalists presented at the 2023 DoD Maintenance Symposium in San Diego, CA on 18 December. Four of those finalists provided presentations during this technology forum.
Welcome: John Shultz, ODASD (Materiel Readiness), welcomed everyone to the forum, and provided a brief introduction of the significance of the DoD MIC in helping to identify and accelerate maintenance innovations within the DoD community.
Administrative: There were approximately 40 people in attendance on the open forum. The presentations, along with questions and answers, were conducted through MS Teams which also offered a chat capability for comments and Q&A. Each presenter provided an approximately 25-minute brief of their MIC innovations plus Q&A. The presentations can be found on the 2023 DoD Maintenance Symposium website under “Programs” for 18 December. A direct link to the combined presentations is below:
3 in 1 Portable Surface Preparation System – Scott Meller (Atmospheric Plasma Solutions, Inc.). The PlasmaBlast technology is an easy to use, mobile tool that will accelerate small scale coating removal operations without negatively impacting the health of the operator or the underlying substrate. PlasmaBlast requires no media, generates no waste streams beyond the removed coating, allows for debris capture, presents no undue occupational or environmental hazards to the operators, and can remove partial or whole coating layers across a wide variety of platforms. The complete elimination of media to remove coatings reduces the de-painting waste stream by more than 95% which provides environmental benefits, increases efficiency, and lowers costs. The PlasmaBlast system sets up quickly, with only electricity and compressed air as inputs (no media or chemicals) and is quickly deployed to forward operating locations. It has been deployed and utilized across the depth and breadth of the DOD including Public and Private Naval Yards, Army Depots and Arsenals, National Guard Camps, and forward operating maintenance facilities.
Identifying Aircraft Pressurization Leaks Using Acoustic Imaging – CMSgt Edward Marchbanks (439 Maintenance Squadron, Westover ARB). Acoustic imaging cameras very accurately pinpoint pressure leaks and overlay this information on a camera image. Utilizing an array of microphones tuned to the ultrasonic frequency of pressure leaks these cameras can triangulate the location of leaks from up to 20 feet away. On-aircraft testing demonstrated their operational effectiveness in the loud flightline environment, easily distinguishing the sound of leaks from the background noise. These cameras also provide technicians with the ability to peer into confined spaces typically inaccessible during pressurization runs due to personnel safety concerns. The technology quickly verified leaks found using traditional methods and easily identified many more leaks that traditional methods could not find. The ability to save the camera images for reference reduced repair times and the need for rework. In addition, the cameras have applications both on-and-off aircraft and can be used to identify leaks in any compressed gas system. Use of this innovative technology will increase overall aircraft availability across the majority of MDSs by reducing maintenance downtime. The ability to identify pressurization leaks quickly and more accurately will eliminate rework, reducing both manhours and fuel costs. These cameras are adaptable across all airframes and can be easily implemented for use in the field, ISO/Phase docks, and Depot locations.
Blue Light Scanner – Leonel Narvaez (Corpus Christi Army Depot). Blue Light Scanning (BLS) provides mechanics with an alternative automated inspection tool for performing component overhaul inspection procedures. This technology helps with reducing inspection times, complex surface comparison, component handling and executes sequence of events for performing examination. Reports are tailored to meet technical requirements in an electronic format. Data captured during scanning is saved by part number and serial number and is stored for future analysis. Time studies comparing legacy inspection methods and BLS demonstrate reduction of inspection times by a 30% with minimal handling of the part. By combining an automated system with the appropriate fixture, the inspection sequence and steps is guaranteed. CCAD is currently deploying BLS technology for the inspection of aircraft transmission components and plans to deploy additional BLS scanners to other component inspection activities to both decrease inspection times and decrease component fallouts.
Spray-able Bushing For Aircraft Wheels – Stoney Middleton (FRCSW) summarized the development of the F/A-18E/F Super Hornet and EA-18G Growler Main Landing Gear (MLG) wheel bore repair using Low Pressure Cold Spray (LPCS) technology. The equipment used for this repair development is Inovati’s Kinetic Metallization™ system, also known as LPCS. A majority of the testing conducted was made possible through a NAVAIR SBIR funded by the Aircraft Equipment Reliability and Maintainability Improvement Program (AERMIP). A qualification test plan was made based on the Original Equipment Manufacturer (OEM) requirements for a new Super Hornet wheel. F/A-18 Fleet Support Team (FST) Landing Gear cognizant engineering approved the test requirements. Repaired wheels had both the inner and outer bores machined to a minimum thickness then cold sprayed to restore original dimensions. The LPCS coating is a metal matrix composite consisting of an aluminum alloy and nickel. The qualification requirements were initially designed for a newly manufactured wheel to complete, not a repaired wheel. After review of the SBIR testing results the risk from a Materials Engineering standpoint appears to be low in the worst case. Additionally, the LPCS process reduces parent material removal (i.e., strength conserved). The LPCS bore repair is now beginning to be implemented at FRC-SW and other platforms such as F-16 and F-35 are considering this repair process.
Q&A – Q&A occurred during and after each briefer conducted their presentation.
Closing Comments: Ray Langlais, ODASD(Materiel Readiness) thanked the panelists and participants for their attendance and discussions on the MIC technologies presented and all the work being done to support the development and implementation of maintenance innovations in support of DoD operations.
Action Items:
- None
Next JTEG Meeting: The next scheduled JTEG virtual forum is 27 February 2024, 1:00 – 3:00 pm EST. The topic is “Laser Coating Ablation”.
POC this action is Ray Langlais, rlanglais@lmi.org, (571) 633-8019