Armament Directorate (EB) Digital Materiel Management
AFLCMC Armament Sustainment Division provides support to Weapons and Missiles across the Air Force and FFMS partners. Weapons Engineering, EBWEW, maintains OSS&E for 570 systems encompassing SOF/Personnel Rescue weapons, 20mm & 30mm guns, Fighter & Bomber Bomb Racks, and Small Arms. This includes noted systems such as the GAU-8 Avenger Cannon, the Vulcan Cannon Family, all bomb racks and missile launchers, AIM-9, HARM, and crew-served weapons such as the .50cal GAU-18. While most of these systems are time-worn, they are still integral and will continue to be utilized in the future Air Force.
Modeling
AFLCMC/EB started its foray into Digital Material Management in 2009 to support a supply system struggling to meet warfighter demands using traditional engineering data and manufacturing techniques. This began with the goal of transitioning all 2D drawings to 3D CAD models. There are over 15,000 parts of which 84% are modeled and 78% have been validated/verified. The Armament Integrated Product Teams (IPTs) approached this challenge using two different paths: external and internal model creation.
3D Model Based Definition: GAU 8/A – 30mm Cannon(Top), 20mm Vulcan Entrance Unit (Left),
Element Guide (Right)
The aircraft guns IPT, managing the GAU-8 and Vulcan cannons, suffered from a 50% failure rate in the First Article Testing (FAT) of spare parts and end item availability was low. Investigation revealed vendors often misinterpreted legacy technical data leading to dimensional errors. EBW engineers determined the long-term solution to be the development of Model-Based Definitions (MBD) of parts that would be provided to vendors. The IPT contracted with the guns’ OEM, General Dynamics Ordnance and Tactical Systems (GDOTS), to create the models but remained highly involved in the development and checking processes as GDOTS had not adopted modeling then. As models are accepted, they are validated through the spares purchases back to GDOTS. This effort is expected to reduce FAT failure rates to approximately 10% as 3D Technical Data Packages (TDPs) and models are made available for procurement.
“Failure rates for First Article Testing expected to reduce from 50% to less than 10%.”
The Bomb Racks IPT also took the approach of contracting for the modeling process. Two contractors were utilized to model 75% of the current systems supported by the IPT. The identified systems are 90% of the workload for the IPT. The total cost for bomb rack contracts was approximately $7M.
The Special Operations Forces/Personnel Recovery (SOF/PR) IPT took an internal approach, where it utilized the engineering team to model and validate the components. This approach had the benefit of avoiding contractor costs. However, the modeling of current systems began approximately 6 years ago, and the modeling process continues for new systems transferring to the team.
During this long process, AFLCMC/EB began tackling the issue with storage and configuration management of the completed models. The organization used Sustainment Engineering funds (EEIC 583) to create of Armament Teamcenter (A-TEAM) to be the model repository and configuration management tool. This system morphed into the A-TEAM system which forms an integral component of the enterprise-wide AF-PLM system.
“Sustainment Engineering funds helped create A-TEAM, a model repository and configuration management tool, now a crucial part of AF-PLM.”
The organization’s engineers utilize the models to accelerate engineering decisions through manipulation and simulation of the models. This improved engineering disposition response times from 2 hours to less than 30 minutes. The models have been used to redesign features causing jams on the 20mm Vulcan cannon. Models have been utilized to design and rapidly iterate on several support components and gauges used across the Air Force.
“Reduced engineering disposition response times from 2 hours to less than 30 minutes. The models have been used to redesign features causing jams on the 20mm Vulcan cannon.”
Additive Manufacturing
Advanced Coatings
EBW utilizes DMM to accelerate the development and evaluation of new technologies supporting our systems. The sharing of models has simplified and streamlined communication between EBW and partners. Numerous Small Business Innovative Research (SBIR), Small Business Technology Transfer (STTR), and Rapid Innovation Fund (RIF) vehicles have been utilized to research advanced coatings, cold spray technologies, and other material advances. These technologies are being implemented across EBW’s portfolio and have been integral in improving several AM components.
“The sharing of models has simplified and streamlined communication between SPO and partners.”
15K Round Comparison between legacy phosphate coating and DLC.
Compared to legacy coatings, DLC is a promising coating for wear, reducing the need for lubrication and increasing part life due to the low coefficient of friction and high hardness. The coating has been applied to AM INCONEL 718 parts to improve mechanical properties and increase the potential life of the AM parts compared to legacy parts. Live fire testing on the 20mm cannon system with INCONEL 718 parts coated with the DLC has shown minimal visible wear reduction compared to a traditional phosphate-coated part. Live fire testing for a fully coated 30mm GAU 8/A gun is planned and will provide data on DLC use on ferrous alloys in the harshest of environments and potentially allow for DLC as an alternative to phosphate coating parts.
Plasma Electrolytic Oxide (PEO) coating is another wear-reducing, advanced coating for aluminum components. EBW has applied PEO to the missile launcher rails with a 5x lifespan extension. This drastic improvement has become the standard coating for the components and has saved millions in material and repair costs.
Advanced barrel coatings of various compositions are being pursued via multiple avenues to eliminate the use of Hexavalent Chrome, a known carcinogen, and increase the service life of the barrels. One of the candidate coatings, Nanovate Cobalt-Tungsten (nCoW), is currently preparing for full Lifecycle testing on a phase III SBIR, and another, Amorphous Chromium-Carbide (a-CrC), is undergoing initial testing in a Phase II SBIR. The ability of the coatings to survive in the complex and harsh environment of medium-caliber gun systems can lead to applications in other components that are still reliant on hard chrome.
Summary
The AFLCMC/EB Armament Sustainment Division is revolutionizing the sustainment of weapons systems through innovative applications of digital modeling, additive manufacturing (AM), and advanced coatings. The division has improved engineering decision response times by 75% and expects to see reduced FAT failure rates using MBD. AFLCMC/EB has also achieved significant breakthroughs in AM, engineering complex components such as the GAU 8/A lubricator housing with improved material properties and reduced flaws, resulting in potential life extension and reduced wear. Additionally, the division is pioneering advanced coatings, such as diamond-like carbon and plasma electrolytic oxide, which have achieved remarkable results, including significant wear reduction and a 5x lifespan extension on missile launcher rails. These innovations are enhancing existing technologies and paving the way for new ones, ensuring the Air Force remains the vanguard of aerial domination with more advanced and resilient weapons systems.
