SAFE ENGINEERING, INC.saf-engineering.com/Publications/SAFE-Aeronautica-Aerotage_SOC.pdf · Major STC Installations Auxiliary Fuel System VIP Interior Entertainment System IFE installation

SAFE INC.

A Service Disabled Veteran Owned Business

[email protected] 3290 Hamal Circle

Monument, CO 80132 (719) 375-5855

Who We Are • SAFE Inc.

– Dr. Scott A. Fawaz, Professional Engineer, FAA DER

– 25 years Aerospace Engineering experience

– Highly successful Service Disabled Veteran Owned Business

– IDIQ contracts, R&D contracts, Grants and Cooperative Agreements

– James S. Burd, FAA DER

– 25 years Aerospace Engineering experience

– 14 years as FAA DER in Stress design and construction, fatigue and damage tolerance

– Provides engineering and certification services to various customers in support of in service repairs, modifications and replacements to major airframe structural components

– Brad Hardwick

– 30 years experience in avionics

– Provides innovative aircraft systems integration engineering and certification to the aerospace industry with technical avionics expertise

– Specializes in comprehensive electrical and structural design data packages for installation on both civil and military applications

What We Do • SAFE Inc.

– USAF Aircraft Structural Integrity Program (ASIP)

– Durability and Damage Tolerance Analysis • Fracture Mechanics

• Environmentally Assisted Cracking

• Classic Fatigue Analysis

– Design and Analysis of Aircraft Structure

– Computational Structural Mechanics • Finite Element Analysis

• High Performance Computing

– Design of Experiments • Static and Fatigue Test Plan Development

• Test Fixture and Specimen Design and Analysis

– Failure Modes and Effects Analysis

– Reliability and Risk Analysis

– FAA 14 CFR Part 25, Part 23 Aircraft • Static Analysis, Fatigue Analysis, Design & Construction, M&P Metallics, Damage

Tolerance Analysis, Major Repairs and Alterations

What We Do • SAFE Inc. cont.

– Software Experience

• Finite Element Analysis – MSC PATRAN/NASTRAN, ZIP3D, CRACK3D, COSMOS/M, STRIPE

• Fracture Mechanics – AFGROW, NASGRO, CRACKS2000

• CAD/CAE – SolidWorks / CATIA

• Numerical Analysis – MathCAD

• High Performance Computing – C/C++, FORTRAN, Unix/Linux, Shell Scripting, Batch Computing

• Office Automation – Microsoft Office Suite, Microsoft Project, Microsoft Publisher

What We Do • SAFE Inc. cont.

– Avionics and Systems Integration • Electrical Load Analysis

• Electrical Substantiation

• System integration design to ARINC 758 and ARINC 750 standards

• Installation Drawings and Instructions

• Assembly Orders

• ATA 100 Format System Wiring Diagrams

• Functional Hazard Assessment

• EMI Test Plan

• EWIS Analysis

• Ground Functional Test Procedures

• Airplane Flight Manual Supplement

• Instructions for Continued Airworthiness

• System Safety Analysis

• Pilot Evaluation Test Plan

• Certification Functional Test Plan

• Certification EMI-EMC Test Plan

• NVIS Evaluation Test Plan

Project Portfolio Organization

Period of

Performance Contract / Grant Number End Customer

United States Air Force Academy 09/26/2011

09/25/2015 FA7000-11-2-0011 USAFA/DFEM-CAStLE

Sabreliner Corporation 10/19/2012

07/27/2015 FA7000-10-D-0014 KC-135 Program Office

Lufthansa Technik 12/15/2012

- N/A Lufthansa Technik

L-3 Mission Integration 03/18/2013

- N/A L-3 Mission Integration

Strategic Applications International

Corp (SAIC)

02/03/2012

09/30/2012 N00178-04-D-4119, DO FG02 OuSD/AT&L

Logistics Management Institute

(LMI)

01/20/2011

09/30/2013 N/A OuSD/AT&L

Total Solutions, Inc. 07/11/2011

07/10/2012 FA7000-09-D-0022-0031 USAFA/DFEM-CAStLE

Avenger Aircraft and Services, LLC 04/25/2011

12/21/2012 N/A Various

Council for Logistics Research, Inc. 09/01/2011

09/30/2011

GS-OOF-0001P/

GST0709BG0108/PT579007

SAF/AQX Acquisition

Integration

Total Solutions, Inc. 05/26/2010

05/25/2011 FA70011-09-D-0022-0006 USAFA/DFEM-CAStLE

• Department of Defense • Avenger Aircraft and Services, LLC

• OuSD/AT&L, Corrosion Policy & Oversight

• Total Solutions, Inc.

• U.S. Air Force • Science Applications International

Corporation (SAIC)

• U.S. Air Force Academy • Logistics Management Institute (LMI)

• U.S. Navy • Sabreliner Corporation

• Lufthansa Technik

• L-3 Mission Integration

Customers

Experience

Wing Strain Analysis

ASIP and Testing

Structural Teardown & Failure

Analysis

ASIP and Structural Teardown

& Failure Analysis

ASIP

ASIP and Structural Teardown

& Failure Analysis

Wing Weep Hole Cracking

Crack Growth from Cold-

Worked Holes

Static Strength, Fatigue,

Damage Tolerance Analysis

Structural Teardown & Failure

Analysis

Static Strength, Fatigue, Damage Tolerance, Full Scale Testing

Fatigue, Damage Tolerance

Analysis of Major Modification

Experience (cont.)

Crack Growth Analyses of

Structural Repairs & Modifications

Static & Fatigue Analysis of Composite

Radome Installed on Fuselage

Full Restoration Effort: Service

Bulletins, NDT Procedures, Analysis and Design of Structural Repairs

Damage Tolerance Assessments of

Major Structural Modifications

Fatigue and Damage Tolerance

Analysis

Development of Internal Fatigue Loads,

Spectrum & Crack Growth Analysis

Service Bulletins, Damage Tolerance Assessments, Aging Aircraft Programs

Developed FAA Certification Plan,

Supplemental Structural Inspection Document (SSID), NDI Requirements

& Procedures

Fatigue and Damage Tolerance

Certification, MRB Support

MRB Support

Static & Fatigue Analysis of Composite

Radome Installed on Fuselage

Stress Analysis

Experience (cont.)

Design, Static & Fatigue Analyses of Major Repairs and Alterations

Supplemental Inspection Maintenance Program

Service Bulletins & NDT Inspection

Programs

Structural Engineering & Certification for

Major STC Installations

VIP Interior Entertainment System Auxiliary Fuel System IFE installation data package VIP Interior Cabin Lighting, Cabin Telephone, Aero H Satellite

Communication, Satellite Television, High-Speed Data/Cabin Network,

Passenger Address and Entertainment Camera

TC electrical design data package restructure, Electrical Load Analysis

Avionics Upgrade and Medical Interior

ACARS and VHF 3 Supplemental Type Certificate

- FAA Approval of Numerous Major Structural Repairs and Modifications - FAA Approval of Structural Drawings and Designs in Support Type Certification Efforts - Development and Co-ordination of FAA Certification Plans for TC and STC Projects - DER Approval of Numerous Static Strength and Damage Tolerance Analysis Reports - DER Recommend Approval of Numerous Instructions for Continued Airworthiness - Led Safety Evaluations for Service Related Issues - Provided and Successfully Obtained FAA Approval of AMOC’s

FAA DER Experience

Testing and Facilities Capabilities

• Prototype/Test Specimen Fabrication – CNC Mill (2), CNC Lathe (2), Digital Mill, Digital Lathe, Electro-Discharge

Machine (Wire and Plunge), Rapid Prototype Machine, Surface Grinder, Standard Workshop Machines and Tools

– Water Jet Cutting – Low and High Speed Saws, Wire Saw Cutter – Plasma Cutting, Tungsten and Metal Inert Gas Welders (TIG and MIG) – Autoclave, filament winder, wet/dry composite lay-up – “Heat Table” – high ∆T, ∆P

• Material Processing – High Temperature Furnace 2200°F(4) – Ultra High Temperature Furnace 3100°F, with controlled environment – Cold rolling mill – Fastener hole cold working

• Analysis and Modeling Tools – 3 supercomputers – Multiple wind tunnels

Testing and Facilities Capabilities (cont.)

• Metallographic/Fractographic – 2 Scanning Electron Microscopes (SEM), Energy Dispersion Spectrometry

(EDS), Backscatter Detectors, Electron Backscatter Diffraction (EBSD)

– Dual Beam Electron Microscope – Focused Ion Beam (FIB) Nanolab

– Atomic Force Microscope

– 4 Stereo Optical Microscopes with Digital Image Capture and Analysis

– Automated Image Analysis Equipment

– Automated Metallography Specimen Preparation Equipment: Automatic Mounting Press, Automatic Grinding and Polishing, Electro-polishing, Electrochemical and Plasma Etching

– Analytical Weighing Balance

– Enclosed flood coolant Cut off Station

Testing and Facilities Capabilities (cont.)

• Material Characterization – Macro-hardness Testers (2), micro-hardness tester, nano-indenter – Ultrasonic C-scan, Eddy Current Surface Scan (ECSS) and Eddy Current Hole

Probe (ECHP) – Differential Thermal Analyzer (DTA), Differential Scanning Calorimeter (DSC),

and Dynamic Mechanical Analyzer (DMA) – Conductivity Meter and Capacitance Meter – X-ray Diffractometer – Chemical composition/identification equipment, Quanta Desk Optical

Emission Spectroscopy – 4 Computer Controlled Potentiostats/Galvanostats for Electrochemical

Measurements – Scanning Vibrating Probe to monitor surface corrosion current – Automated Electrochemical Impedance Spectroscopy (EIS) scanning table

Testing and Facilities Capabilities (cont.)

• Mechanical Testing – Computer Controlled Mechanical Test Frames, 120 kip (1), 50 kip (1), 25

kip (5) – Computer Controlled Servo Hydraulic Test Frames (MTS Flex-Test), 220

kip (1), 110 kip (1), 55 kip (3), 22 kip (2), 11 kip (2) – Vibration shakers (2) – Thermal Environment Chamber for MTS Testing – Computer Controlled Creep testing frames with static and dynamic

loading for temperatures up to 2200°F – Salt Fog Chamber – 3-D Digital Image Correlation – Laser Doppler Vibrometer – Roll around LabView Data Acquisition and Control Carts (4)

Publications

• Archival Journal – 8

• USAF Technical Reports – 9

• Conference Proceedings - 43

References

• Dan Dunmire, Director-CPO, OuSD/AT&L

• Dr. Greg Shoales, Director-CAStLE, USAF Academy

• Sandy Reyes, Contracting Officer, USAF Academy

• Dr. Larry Butkus, Air Force Research Laboratory

• Craig Matzdorf, NAVAIR

• Dr. Robert Piascik, NASA Langley Research Center

• Patrick Safarian, Seattle ACO, FAA

• Ed Ingram, Lockheed Martin

• Prof. Richard Gangloff, University of Virginia

EVALUATIONS and AWARDS

• USAF Research and Development Engineer of the Year, 2006 (Dr. Scott A. Fawaz)

• Frank J. Seiler Research Award for Research Excellence in Engineering, USAF Academy, 2003 (Dr. Scott A. Fawaz)

[email protected] 3290 Hamal Circle

Monument, CO 80132 719.375.5855

A Service Disabled Veteran Owned Business