Overview
Project Number: A2960
Project Title: Automated Laser Coating Removal
Period of Performance: APR23 – APR26
Objective
The objective of this joint project that includes the Institute for Manufacturing and Sustainment Technologies (iMAST), Naval Shipbuilding and Advanced Manufacturing (NSAM) Center, and Air Force Life Cycle Management Center Rapid Sustainment Office is to develop an automated coating refurbishment system to replace the current labor-intensive, hand-sanding process used to remove a very prescribed thickness paint layer in a scuff and refresh effort. The extensive removal time reduces platform (aircraft and part) availability and increases costs associated with refurbishment. In addition, errors in hand-sanding on complex geometries can lead to damage of the composite substrate, which can further increase costs, extend downtimes, and reduce mission readiness.
The joint project team is leveraging the existing F-16 laser coating removal system as a baseline system to be modified to accommodate all F-35 aircraft variants. The Navy team, comprised of the F-35 Joint Program Office (JPO), Fleet Readiness Centers (FRC), Penn State Applied Research Laboratory, Advanced Technology International, Titan Robotics, and Lockheed Martin Corporation (LMCO), is developing technology and transitioning an automated process for measuring and removing F-35 coatings across tight tolerances and contours. Specific objectives include reducing the time to measure and remove coating by 30 percent and validating the accuracy of the measurement system for in-process requirements as well as remaining coatings.
Benefits/Payoff
The cost benefit of this project arises from a significant reduction in coating removal time (including preparation and cleanup) and inspection. For the first aircraft, this process took about 1,000 hours, with 30 percent of the time spent on masking and measuring and 70 percent on stripping and repainting. Using conservative estimates to account for the future learning curve of the alternative process, the team assumed a total objective time savings of 300 hours per jet. DoD is estimating coating refurbishment activities over the span of five years to equate to $13.5M in savings.
Implementation
Implementation is planned for sustainment operations at Air Force and Navy depots. The Air Force is funding all investigations related to the F-35 variant, including any modifications required to the existing full aircraft stripping system currently at Ogden Air Logistics Center. The Navy is working with Commander Fleet Readiness Center (COMFRC) and JPO to help fund prototype equipment fabrication and installation at an F-35 maintenance facility such as a Fleet Readiness Center (FRC) upon completion of this project. FRC coordination has been an ongoing activity throughout project development and execution, where project support has been confirmed as a means to reduce future sustainment costs for F-35. Implementation of this project requires successful and precise partial coating removal, accurate measurements of coating thickness, and the ability to expand surface coverage. Qualification and certification approvals by LMCO and JPO authorities are necessary for implementation.
*Prepared under ONR Contract N00014-24-D-7001 as part of the Navy ManTech Program.
*DISTRIBUTION STATEMENT A. Approved for public release: distribution unlimited. DCN# 2024-10-17-189 ; Approval Date: 10/24/2024
