Problem/Impact: The Inspection And Repair Cell (IRPC) is a direct response to the need for increasing in-service time for expensive, critical composite structures by reducing both cost and cycle time for their required maintenance. The team has targeted the C-130 Nose Radome at the Warner-Robins ALC to demonstrate the production ready processes to be delivered by the IRPC. The first phase 1 of the program has been devoted to qualifying individual NDI processes and other advanced processes, and phase 2 will be utilized for performing the functions required , employing the individual processes, in the machine tool/work cell environment and constraints. The manual operations to be automated include detection of defective areas (tap test), scarfing to remove the defective composite skin, removal of crushed core, preparation of replacement core plugs, and preparation of dry fabric plies for repair. Advanced processes being utilized include digitization, shearography, laser projection, and microwave based inspection. While the demonstration IRPC Project has focused on a specific component, the proposed work cell will be applicable to the repair of many different types and sizes of large composite structures. He advanced processes can be implanted individually, or in various combinations.
Benefit: IRPC is envisioned as a project to demonstrate an annual savings of $1,987K across three components at Robins AFB along with significant reductions in flow days that would achieve a less than two-year pay back. Multiple other potential applications exist in addition to Warner Robins ALC.
Impact on Warfighter: The IRPC project is a direct response to the need for increasing in-service time for expensive, critical composite structures by reducing both cost and cycle times for their required maintenance.
DoD Participation:
- U.S. Air Force
- U.S. Navy
- U.S. Army
- AFRL Composites Directorate
- AFRL NDI Directorate
Industry Participation:
- GFM
- Assembly Guidance Systems
- Steinbichler
- Manufacturing Resources, Inc. (MRI)
- Boeing
- Picometrix, LLC
NCMS Project Manager: Bill Waddell (231)264-9774
