Defense

June 27, 2012

Research lab helps solve C-5 cracking issues

by Holly Jordan
Wright-Patterson AFB, Ohio

An AFRL-developed process produces all 92 end fitting shapes with just two separate forging dies; the end fittings significantly decrease the a cracking issue in the C-5 bulkhead floor.

Newly developed structural technologies developed by the Air Force Research Laboratory have solved critical cracking issues with the C-5 cargo aircraft, thereby expanding the aircraft’s serviceability.

As part of the Durable C-5 Structural Improvements Program, AFRL recently investigated cracking issues that have been occurring in C-5 cargo floor bulkhead end fittings, part of the under-floor structure in these large cargo vehicles. The cracks, caused by stress corrosion, led to increased maintenance cost, and had the potential of reducing the amount of cargo the C-5s carry.

Traditional repair methods proved insufficient because replacement fittings would often crack during the machining process, and had a shorter lifespan than original parts. To solve the problem, researchers looked into a new, more stress corrosion-resistant aluminum alloy and a new die forging process by which all 92 fitting shapes required for the C-5 bulkhead floor could be produced using only two separate forging dies.

This new process saves money, time and effort. Additionally, the reshaped fittings created by the forging process yield an optimized design less prone to cracks. The new end fittings will provide numerous benefits for the retrofitted C-5 vehicles, including a 25 percent overall cost savings, an 80 percent reduction in fabrication time, and a 60 percent increase in service life of the fittings.

This technology has been transitioned to the Warner Robins Air Logistics Center, Ga., where the new end fittings have been installed in select C-5 aircraft. Additionally, AFRL researchers say this forging process can be applied to other aircraft that experience the same cracking issues.




All of this week's top headlines to your email every Friday.


 
 

 

Headlines August 31, 2015

News: Pilot killed in crash was helping wounded veterans – A pilot who died in a small plane crash in the desert northeast of Los Angeles was giving free glider rides to wounded military veterans. Turkey carries out first air strikes as part of anti-Isis U.S. coalition – Turkish fighter jets have carried out their first air...
 
 

News Briefs August 31, 2015

Pakistan officials: U.S. envoy discusses Afghan peace efforts Pakistani officials say visiting U.S. National Security Adviser Susan Rice has discussed efforts to revive Afghan peace talks. Rice met with Prime Minister Nawaz Sharif and army chief Gen. Raheel Sharif Aug. 30. Two Pakistani officials say they discussed efforts to revive talks between the Afghan government...
 
 
Courtesy photograph

F-22 inaugural deployment to Europe

Courtesy photograph A pair of F-22 Raptors fly near the coastline of Panama City Beach, Fla. Four F-22 Raptors, one C-17 Globemaster III, and approximately 60 airmen arrived at Spangdahlem Air Base, Germany, to train with allie...
 

 
ILS photograph

Boeing-built satellite will create first global high-speed broadband network

ILS photograph The Inmarsat-5 F3 satellite launched Aug. 28 aboard a International Launch Services Proton Breeze M rocket from Baikonur, Kazakhstan. EL SEGUNDO, Calif.–When the third Boeing-built [NYSE: BA] Inmarsat-5 sat...
 
 

Civil Air Patrol joins total force ‘Airmen’

When conducting missions for the Air Force as the official Air Force auxiliary, the Civil Air Patrol is now included in the Air Force’s definition of the total force. CAP has provided 74 years of support to emergency services, aerospace education and cadet programs. In August 2015, the Air Force updated Doctrine Volume 2, “Leadership,”...
 
 
DOD photograph by Air Force MSgt. Adrian Cadiz

Carter announces manufacturing initiative to aid war fighters

DOD photograph by Air Force MSgt. Adrian Cadiz Defense Secretary Ash Carter announces the creation of a National Manufacturing Innovation Institute to produce hybrid electronics during a speech at the National Full Scale Aerody...
 




0 Comments


Be the first to comment!


Leave a Reply

Your email address will not be published. Required fields are marked *

You may use these HTML tags and attributes: <a href="" title=""> <abbr title=""> <acronym title=""> <b> <blockquote cite=""> <cite> <code> <del datetime=""> <em> <i> <q cite=""> <s> <strike> <strong>