Overview
Project Number: A2979
Project Title: Improved Leak Detection
Period of Performance: FEB24 – DEC25
Objective
Throughout F-35 production, pressure tests are performed on structures and systems to ensure there are no leaks as a part of the aircraft assembly process. For fuel, pressure leak checks occur within the wing systems, final assembly, on the flight line, and throughout aircraft sustainment. These pressure checks occur periodically for every aircraft to ensure internal fuel tanks and systems that traverse these fuel tank cavities meet integrity specification prior to aircraft fueling.
The objective of this Naval Shipbuilding and Advanced Manufacturing (NSAM) Center project is to investigate and improve methods to detect and isolate leaks from F-35 tanks within the production and sustainment phases. The project will enable mechanics to quickly and accurately identify and troubleshoot leaks on aircraft by investigating relevant technologies, modifying and evaluating leak detection systems in a production and sustainment environment and then developing and demonstrating a prototype detection system. The resulting technology is anticipated to enable aircraft technicians to quickly identify and troubleshoot leaks on aircraft (production and sustainment), improve leak detection accuracy, and further increase confidence in leak detection technology to potentially allow for application beyond F-35 production.
Benefits/Payoff
Once implemented, it is anticipated that this project will reduce the hours needed to perform leak detection tests by ~20 hours for each aircraft in production (baseline is 27 hours) and ~17 hours in sustainment. Implementation of new technologies and processes developed under this project is estimated to result in a five-year savings of $1.43M for the F-35 program. Additional benefits include increased fleet readiness, reduction in required maintenance time at maintenance depots, flight safety and airworthiness, and elimination of a subjective process indicators.
Implementation
The anticipated first year of implementation is FY2026, with the final year of implementation being FY2031. The technology will be implemented at Lockheed Martin Aeronautics on the F-35, with 413 aircraft being built during the implementation period. The technology will also be implemented at Cherry Point on the F-35, with 400 aircraft being serviced during the implementation period.
*Prepared under ONR Contract 00014-24-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
