UNCLASSIFIED NonExport Controlled Information A Corrosion Management System

UNCLASSIFIED Non-Export Controlled Information A Corrosion Management System for Rotary Wing Aircraft Dr. Aaron D. Sudholz Engineering Manager Corrosion Group BAE Systems Australia Copyright © 2019 BAE Systems. All Rights Reserved. 1

UNCLASSIFIED Non-Export Controlled Information Outline • Condition-based Maintenance. • Corrosion Prognostics and Health Management (CPHM). • CPHM Architecture. • Hardware. • Software. • System Trials: • Seahawk Bravo; • ARH Tiger. • Summary. • Questions. Copyright © 2019 BAE Systems. All Rights Reserved. 2

UNCLASSIFIED Non-Export Controlled Information 3 Condition-Based Maintenance (CBM) • • Follows Failure Mode, Effects, and Criticality Analysis (FMECA). Similar to RCM, but uses sensors and models to enable more definitive diagnostics. Optimize maintenance and costs. Relies on good data: as per the adage “garbage in, garbage out”. Copyright © 2019 BAE Systems. All Rights Reserved. https: //images. defence. gov. au/assets/

UNCLASSIFIED Non-Export Controlled Information CPHM System: Managing ASI • • Corrosion Prognostics Health Management (CPHM) system. Forms part of a complete Aircraft Structural Integrity Program (ASIP). BAESA have 35 years of experience in HUMS expertise adapted to CPHM. Copyright © 2019 BAE Systems. All Rights Reserved. 4

UNCLASSIFIED Non-Export Controlled Information CPHM System: Architecture On-board: • Environmental data collected per location per aircraft. Off-board: • • Aircraft data integrated with other databases/sources. Quality check and approval to ensure appropriateness of input data. Determine current and/or future corrosion condition using science-based modelling. Publish outputs to the user/decision maker via software interface. Copyright © 2019 BAE Systems. All Rights Reserved. 5

UNCLASSIFIED Non-Export Controlled Information Hardware: Sensors Trial sensor suite developed by Defence Science and Technology Group (DST Group). Sensor suite (40 mm × 52 mm × 22 mm) comprise: • • Ambient temperature. Surface temperature. Time-of-wetness (TOW). Relative Humidity. The electronics comprise: • • • 4 year lithium battery. Low-power microcontroller. Non-volatile memory. Real-time clock. Wireless 916 MHz transceiver. Trans-impedance logarithmic amplifier for TOW sensor. Copyright © 2019 BAE Systems. All Rights Reserved. 6

UNCLASSIFIED Non-Export Controlled Information Hardware: Witness Plates Multi-Alloy Witness Plate (MAWP): 1. 2. 3. 4. 5. • • AA 2024 -T 351. AA 2124 -T 851. AA 7050 -T 7451. AA 7075 -T 651. AA 7085 -T 7651. New alloys compared with well studied legacy alloys. Duplicate coupons (10 mm × 10 mm). Copyright © 2019 BAE Systems. All Rights Reserved. 7

UNCLASSIFIED Non-Export Controlled Information Software: EDMAP • • Environmental Degradation Monitoring And Prognostics (EDMAP). Includes embedded science-based modelling to estimate corrosion damage. Loads, filters, and displays a range of monitored sensor data. Allows diagnostics and prognostics of corrosion condition. Facilitates maintenance planning. Schematic shows monitored zones on aircraft. Uses ‘traffic light’ color scheme to show increased likelihood of corrosion. Copyright © 2019 BAE Systems. All Rights Reserved. 8

UNCLASSIFIED Non-Export Controlled Information Software: EDMAP Currently scheduled maintenance opportunities for this aircraft. Currently scheduled maintenance opportunities for this bay. Prognostics Timebar: expected corrosion state over time for each bay. Presents inspection deferral opportunities. Copyright © 2019 BAE Systems. All Rights Reserved. 9

UNCLASSIFIED Non-Export Controlled Information CPHM Trials: Seahawk Bravo • Sikorsky S-70 -B 2 (Seahawk Bravo): Two aircraft fitted with DST data logger, including NAVAIR time-of-wetness sensor. Wireless Data Gathering Units (DGU) used to collect on-board sensor data. Successfully demonstrated wireless data collection – multiple loggers/aircraft. • • Sensors in four locations: 1. 2. 3. 4. Cabin Floor Weapons Pylon Avionics Bay Canted Bulkhead Copyright © 2019 BAE Systems. All Rights Reserved. 10

UNCLASSIFIED Non-Export Controlled Information CPHM Trials: Seahawk Bravo • Trial Details: • • • Aircraft operated out of HMAS Albatross; Base located at Nowra, NSW. 6 month trial in 2017 (before Bravo retirement); Trial aimed to: • Demonstrate data collection from aircraft for CPHM system; and • Support transition to MH-60 R (Seahawk Romeo). Copyright © 2019 BAE Systems. All Rights Reserved. 11

UNCLASSIFIED Non-Export Controlled Information CPHM Trials: Seahawk Bravo Learnings from data: • • Temperature sensor data showed cold-soaked airframe during flight. Subsequent condensation/deliquescence measured by TOW sensor. TOW response scaled with extent of salt contamination. Ability to classify the corrosivity of the operational environments. Copyright © 2019 BAE Systems. All Rights Reserved. 12

UNCLASSIFIED Non-Export Controlled Information CPHM Trials: ARH Tiger • Implementation of Lessons Learned from Seahawk Bravo trial: • • • Make data downloads part of the mandatory maintenance procedures during the trial period. Increase download frequency to ensure no data loss (memory constraints). Improve wireless communications between data loggers and portable data gathering unit. Ensure robust data management infrastructure and procedures. Improve communication and training with assisting personnel. Copyright © 2019 BAE Systems. All Rights Reserved. 13

UNCLASSIFIED Non-Export Controlled Information CPHM Trials: ARH Tiger • • • Armed Reconnaissance Helicopter (ARH). Managed by Taipan Tiger Management Unit (TTMU) (Co. A). ARH operated by Australian Army. • • Looking to extend trial to Multi Role Helicopter (MRH), pending TTMU decision. Managed by TTMU and operated by Australian Army/Navy. • Trial to include 1/3 of fleet (8 and 14 tails respectively). https: //www. army. gov. au/our-future/modernisation-projects/aviation-projects/arh-tiger http: //www. navy. gov. au/aircraft/mrh-90 -taipan Copyright © 2019 BAE Systems. All Rights Reserved. 14

UNCLASSIFIED Non-Export Controlled Information 15 CPHM Trials: ARH Tiger Darwin Locations: • • RAAF Base Darwin. Army Aviation Centre Oakey. Trial Details: • • • Oakey Coastal bases. Trial commenced September 2018. Expected to conclude 2020 -21. http: //www. navy. gov. au/fleet/ships-boats-craft/lhd Copyright © 2019 BAE Systems. All Rights Reserved. • ADF acquisition of two Landing Helicopter Docks (LHD) means ARH/MRH will regularly be exposed to embarked conditions. • Need for an on-condition maintenance tool to assist corrosion management.

UNCLASSIFIED Non-Export Controlled Information CPHM Trials: ARH Tiger Locations of sensors: • • • Main Gear Box (4500). Cockpit (2100/2200). Aft Section (3200). Between Frame 2 and 3 (1200). Between Frame 1 and 2 (1100). Copyright © 2019 BAE Systems. All Rights Reserved. 16

UNCLASSIFIED Non-Export Controlled Information CPHM Trials: ARH Tiger Aims: • • • To validate corrosion models with aircraft trials (witness coupons/aircraft corrosion). To identify corrosion condition transition thresholds. To test the data management process. Some Findings To Date: • • TOW sensors did not correlate between different aircraft locations. RH showed strong correlation between different aircraft locations. Ta and Ts showed strong correlation near Cockpit and surrounding bays, and less correlation with Gearbox and Tail. Trial sensor suite demonstrated EMI susceptiblity in one location. Copyright © 2019 BAE Systems. All Rights Reserved. 17

UNCLASSIFIED Non-Export Controlled Information Summary • Condition-based maintenance (CBM) can assist reducing cost-of-ownership for aircraft. • A CPHM tool can enable CBM. • CPHM architecture incorporates sensors, modelling, and software to provide relevant information to decision-makers. • Current hardware demonstrates necessary environmental parameters for CPHM and the ability to collect this data from on-board locations. • Software developments demonstrate data management and visualisation necessary to make corrosion modelling outputs accessible to decision-makers. • Current CPHM system trials on rotary-wing aircraft have helped refine the technology and demonstrate its scalability to a fleet-wide corrosion management tool. Copyright © 2019 BAE Systems. All Rights Reserved. 18

UNCLASSIFIED Non-Export Controlled Information Questions? Copyright © 2019 BAE Systems. All Rights Reserved. 19