Reliability of New Generation Fastener Drive Systems on Military ...

Reliability of New Generation Fastener Drive Systems on Military Platforms

Ken CampitelliPhillips Screw Company

[email protected]

760-884-67001

Fastener Drive Systems

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Fastener Drive Systems

- Open recess to accommodate heavy coatings- Off-angle driving ability- Full wing contact- Anti-cam out properties

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Fastener Reliability Data

Navy – data not collectedAir Force – data not collectedArmy – data not collectedCommercial Airlines – data not collected

“hey, fasteners are just a consumable item”

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Fastener Failure True Costs

Fastener replacement costDrive bit replacement costDrill bit costDamaged fastener drill out cost/man-hoursHAZMAT- - airborne particles by drilling

(CAD, Chromium, Molybdenum…)Engineering disposition costFastener/bit ordering cost

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Fastener Failure True Costs

Awaiting parts impact costFastener/bit warehouse and inventory

storage costLost production time cost/TATDamaged nut plates/panel/windscreen

costInjury cost

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Fastener Reliability Improvement Team

• US AIR FORCE - C-5 GALAXY• US MARINE CORPS - V-22 OSPREY• US AIR FORCE - B-2 SPIRIT• US NAVY - E-2 HAWKEYE• US AIR FORCE - F-16 FALCON• US ARMY – UH-60/AH-64• US NAVY - F/A-18 HORNET

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C-5 GalaxyUS AIR FORCE

LOCKHEED MARTINGOODRICH

- Undergoing engine upgrades to the GECF-6 engine to improve thrust, fuel efficiency, and reliability. As part of this effort new pylons were developed to support the higher thrust engines.

- The new design incorporated 7 access panels for improved maintenance. Failure rates on the fasteners securing these panels were 10% during initial installation with a 25% scrap rate during maintenance.

- Drilling out failed fasteners and repairing damaged panels was common.

- The redesigned fasteners utilizing the MORTORQ® spiral drive provided a zero failure ratewith no damage to tools or panels.

- Air Force C-5 Program Office approved change– EXPANDING APPLICATION - CONVERTING AIRCRAFT

- Estimated savings in fastener costs on PYLONS ALONE are $7,800 per aircraft.

C-5 Galaxy

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C-5 Galaxy

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USAF C-5Phase 1 Conversion

PMT1153-2 NSN 530-501-600-8384PMT1153V3 NSN 530-501-604-0726PMT1153-4 NSN 530-501-600-0523PMT1153V4 NSN 530-501-603-8116PMT1153V5 NSN 530-501-603-8307PMT1153-6 NSN 530-501-600-9473PMT1153-7 NSN 530-501-600-9481PMT1153-8 NSN 530-501-600-0571PMT1153V8 NSN 530-501-603-8312PMT1153-10 NSN 530-501-600-0611PMT1153-12 NSN 530-501-600-0616PMT1153V12 NSN 530-501-600-9506PMT1153-13 NSN 530-501-600-8461PMT1153-14 NSN 530-501-601-1940PMT1153-15 NSN 530-501-601-1945PMT1153-17 NSN 530-501-600-0489PMT1123-2 NSN 530-501-600-8256PMT1123-3 NSN 530-501-600-8249PMT1123-4 NSN 530-501-600-8315PMT1123-7 NSN 530-501-600-8231PMT1123-9 NSN 530-501-600-0713PMT1123-10 NSN 530-501-599-5488PMT1123-12 NSN 530-501-601-0973PMT1123-13 NSN 530-501-600-0764PMT1123-14 NSN 530-501-600-0727PMT1123-15 NSN 530-501-599-5426PMT1123-16 NSN 530-501-600-0759PMT1154-12 NSN 530-501-600-0667

PMT1154-13 NSN 530-501-600-8371PMT1154-14 NSN 530-501-600-0619PMT1154-15 NSN 530-501-600-0673PMT1621-17 NSN 530-501-600-9514PMT1623-8 NSN 530-501-601-2285PMT601-20P NSN 530-501-600-9639PMT602-20P NSN 530-501-600-9666PMT602-22P NSN IN WORKPMT602-3P NSN 530-501-600-0835PMT115-6-14 NSN IN WORKPMT115-6-15 NSN IN WORKPMT1124-10 NSN 530-501-603-8572PMT1124-12 NSN 530-501-600-8422PMT1124-14 NSN 530-501-600-8308PMT8703-3 NSN 530-501-600-0198PMT8703-4 NSN IN WORKPMT8703-5 NSN 530-501-602-1392PMT8703-9 NSN 530-501-603-8186PMT8703-12 NSN 530-501-603-8154PMT8704A4 NSN 530-501-600-0268PMT8704A6 NSN 530-501-600-8399PMT8704A9 NSN 530-501-600-0321PMT8704A12 NSN 530-501-600-8172PMT8704-4 NSN 532-501-603-2121PMT8704-6 NSN 530-501-613-2236PMT8704-9 NSN 530-501-613-2228PMT8704-12 NSN 530-501-613-2233 11

V-22 OSPREY FRC EAST

MARINE CORPS AIR STATIONNEW RIVER, NORTH CAROLINA

BUNO 165845- Trials began July 2011- Completed Dec 2011 test not to exceed 210 flight hours side by side comparison remove and reinstall every 14 days collect failure data 0% MORTORQ® failure 100% legacy drive/TORX failure

October 17, 2011They are performing amazing. We have yet to change one out. Almost every time we have done the inspection we have had to change out at least six to seven of the original fasteners. There has been no sign of the MORTORQ fasteners losing torque and the wear on them is minimal..

R/SSgt. Kruger, Bryan C. VMX-22/Team ScarletAirframes CDQARTire/Wheel Program Manager

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B-2 SPIRIT US Air Force

Northrop Grumman

- COCKPIT BLAST SCREEN

- NSN530-501-603-1442 - - PMT738U3-10

- NSN530-501-603-1439 - - PMT738U3-12

TRIALS COMPLETED SEPTEMBER 2011

- Converted to MORTORQ® Spiral Drive

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E-2D HAWKEYEL-3 Vertex Aerospace

US NAVYE-2D HAWKEYE RADOME

- SUPPORTED L-3 VERTEX, MENLO PARK, CA + AASC, STOCKTON, CA, ON E-2 RADOME TRIAL DUE TO HIGH FAILURE OF NAS1581/NAS1580

- @25% FAILURE RATE

- JUNE 2013 - NORTHROP GRUMMAN APPROVED LEVEL 1 CHANGE

- NAVAIR APPROVED ECP

E-2D HAWKEYEL-3 Vertex Aerospace

US NAVYE-2D HAWKEYE RADOME

ASSEMBLYTHE IMPLEMENTATION OF THE MORTORQ HEAD DESIGN, THE ASSEMBLY OF THE FWD/AFT TO

MID SECTION HAS BEEN REDUCED FROM A 50 HR AVERAGE OVERRUN TO A 28 HR OVERRUN ON THE AA #12 TASK ESTIMATE TO COMPLETE.

SAVINGS = 12 HRS

DISASSEMBLYTHE IMPLEMENTATION OF THE MORTORQ HEAD DESIGN, THE DISASSEMBLY OF THE FWD/AFT

FROM MID SECTION HAS BEEN REDUCED FROM A 12 HR AVERAGE OVERRUN TO AN 18 HR UNDERRUN ON THE AA #11 TASK ESTIMATE TO COMPLETE.

SAVINGS = 30 HRS 15

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F-16 FALCON

F-16 with wing removed showing bracket locations in main wing structure

- Depot airframe maintainers were experiencing problems achieving the required installation torque on wing bracket bolts with existing drive system, were damaging fastener heads and had high failure rates of tool bits.

- Phillips Screw Company provided sample bolts in the 7/16” diameter with the MORTORQ® Spiral Drive for test and evaluation.

- Lab testing by LMCO - new bolts were able to achieve 1200 lbs-in torque where the legacy drive design was failing between 450 and 900 lbs-in torque.

- Trials at HILL AFB Depot - 100% reliability.

- LMCO engineering drawings updated

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UH-60 BLACKHAWKAH-64 APACHE

- US ARMY/CCAD- UH-60 BLACKHAWK

- Main Rotor Blade Tip Cap- H7883-P5- NAS8403U8

- Tail Rotor Blade Fairing- SS5013-10-24

- AH-64 APACHE- Main Rotor Blade Tip Cap

- HS4396-3T4- HS4396-3T5

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F/A-18A-D/SUPER HORNETUS NAVY

MORTORQ Trials• NAVAIR – AIR 4.0, VX-23, Fleet Readiness Center

Southeast

US NAVY F-18 Depot Maintenance

FLEET READINESS CENTER SOUTHEAST

AUGUST 2011- Commander Fleet Readiness Center Study results:

- “Surfboard” wing panel has 500 High Torque fasteners- Failure rate of @225 per 500 (45% failure)- Use “Pizza Cutter” type fastener removal tool vice standard High Torque as work around due to poor fastener drive reliability

F-18 Line - drive bit costs alone

135 “Pizza Cutter” + 2,377 wheels + 3,553 bits = $303,557.96( + replacement fasteners costs, + labor costs, + damage, +TAT,

+direct/indirect costs, + engineering costs….)19

C-130 Fastener Reliability and Maintainability???

CURRENTLY USED RECOMMENDED

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- BOEING

- AIRBUS

- GOODRICH

- NASA - SPACE SHUTTLE

- FOKKER AIRCRAFT

- ROLLS ROYCE ENGINES

- PRATT AND WHITNEY

- PARKER CONTROLS

- RAYTHEON

MORTORQ® Spiral Drive Commercially In Use

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¼” HEX INSERT BIT Point Size

Overall Length Part Number National Stock

Number

0

1.0"

ZMT-0 TNI0388 5130-01-581-5339

1 ZMT-1 TNI0389 5130-01-581-5340

2 ZMT-2 TNI0390 5130-01-581-5342

¼” HEX INSERT BIT Point Size

Overall Length Part Number National Stock

Number

0

1 5/16"

ZMTP-0 TNI0391 5130-01-581-5341

1 ZMTP-1 TNI0392 5130-01-581-5343

2 ZMTP-2 TNI0393 5130-01-581-5344

Phillips MORTORQ®Spiral Drive Bit

National Stock Numbers (NSN)

OEMBoeing, Lockheed Martin,

Northrop Grumman, Pratt Whitney, Rolls Royce…………

PLATFORMSUS Air Force, US Navy,

US Marine Corps, US Army…………

SUPPLYDefense Logistics Agency, GSA,

DLIS, suppliers……

MANUFACTURERSAlcoa, SPS, Valley Todeco,

Air Industries, John Hassall, North East Fastener, Monogram, Lisi HI-Shear……….

Phillips Screw CompanyFastener Reliability Improvement Team

Phillips Screw CoFastener Reliability

ImprovementTeam

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QUESTIONS?