CAD/PAD Ordnance Assessment (OA) & Surveillance Jeffrey Watts NSWC IHEODTD CAD/PAD Ordnance Assessment 8 April 2017

Overview Purpose Importance of OA Program Background OA Process Steps Summary Sample Firings Questions

Purpose The CAD and PAD Ordnance Assessment (OA) programs assess the quality, reliability, and serviceability of all CAD/PADs to determine if any deficiencies have occurred as a result of aging and/or environmental conditions. What is a CAD? What is a PAD? Cartridge Actuated Device (CAD): Provides the means of releasing/controlling potential/chemical energy by a discrete cartridge and/ or to harness this energy to accomplish a specific work function. Propellant Actuated Device (PAD): A device which provides the means of releasing potential/chemical energy for propulsion and harnessing this energy to accomplish work. Talk types of CADs/PADs

Importance of OA Verifies CADs and PADs are working within the requirements of their intended systems (Aircraft, Weapons, Life support) OA has revealed catastrophic failures, stabilizer depletion, and performance degradation of end-items. Successful evaluations benefit end-users Validate current life Determine if service life deserves increase/decrease Provides consistent evaluation where more than 1 vendor exists Differences in test methods/techniques Different acceptance parameters Different end-item internal designs

Supported Sponsors Programs are currently conducted for: Naval Sea Systems Command Naval Air Systems Command US Air Force US Army NASA FMS Other sponsors (when requested and funded) On average, NSWC IHEODTD conducts 60-70 new OAs yearly

Test Considerations Emphasis is placed on items that have been installed into their intended applications and associated environmental conditions. Representative of the current fleet population Manufacturers and Production Lots Total Ages Also considered: CAD/PAD design or production changes Aircraft configuration changes Material performance / reliability level Logistics needs

Test Frequency New items introduced to the fleet are typically tested 3 years after fleet introduction Subsequent tests 3 year intervals for life support 5 year intervals for aerial target, stores release, and fire extinguisher items (if needed) Out-Year Test Plan reviewed annually Obsolete aircraft or component design Susceptible items New items qualified

Program Controls Sample Availability OA requirement guide/ Out-year Test Plan Item test directives Individual test costs / Funding Complexity of CAD / PAD Types and number of tests to be performed Number of Test Samples Test fixture and procedure availability Stabilizer testing

CAD/PAD sample storage magazine Acquiring Samples Annual sample requirement to Fleet Sample Acquisition initiated at least 1 year in advance Identified by DODIC for upcoming year Administrative Naval Message NSWC IHEODTD rework stock Coordinated with Naval Operations Logistics Support Center (NOLSC) A good OA depends on a good sample A good sample is determined by what we get back from the fleet A quality sample boosts confidence in the test results Fleet Rework Stock Stock Points CAD/PAD sample storage magazine

New Fleet Return Process Automated System Currently only for US Marine Corp., with goal of incorporating all customers Allows specific lots and serial numbers to be identified and pulled directly from fleet Items can be chosen to minimize impact on fleet Enables acquiring samples of interest Past testing issues Extreme service environments Helps determine the worst case and better define the limits of the unit When items are flagged for return, fleet is notified that the item is desired for OA testing Alerted to replace item during scheduled maintenance

OA Process Steps Visual Inspection X-Ray Inspection Non-Destructive Testing (NDT) Visual Inspection Electrical Resistance X-Ray Inspection Hermetic Seal Leak Photo credit: NSWC IHEODTD, Dept E Photo credit: NSWC IHEODTD, Dept E Visual Inspection X-Rays: Voids, cracks, potential environmental impacts X-Ray Inspection

Destructive Testing Normal Conditioning Temperatures CAD: -65, 70, 165, 200oF (-54, 21, 73, 93oC) PAD: -65, -40, 70, 165oF (-54, -40, 21, 73oC) Test Procedures & Fixtures Same as original Lot Acceptance Tests (LAT) in order to maintain commonality. Fixtures designed to simulate end item use or configuration Typical Specification Parameters CADs: Pressure, Time to Maximum Pressure, Thrust, Detonation Velocity, Delay Times, Acceleration, etc… PADs: Thrust, Impulse Acceleration, Dynamic Response Index (DRI), Multi-axial Dynamic Response Criteria (MDRC)

Destructive Testing Example: DODIC M507 (F-4 / EA-6B Drogue Gun Cartridge) specification parameters Ignition Delay Velocity Magnetic Coils Test Fixture Air Solenoid

Statistical Analysis Generated data is compared to LAT and prior OA test data. Plotted as a function of total age and installed time. Reliability Statistics Functional: Performance within specification Catastrophic: Ability of item to complete the firing cycle when initiated. N – Number of samples N’ - Effective sample size Y - mean Se – Standard deviation

Engineering Decisions Does data represent the current fleet population? Sample Quality Safe to store and handle at current lives? Propellant Stability Reliable? Performance within required limits? Statistical Analysis Effects of Fleet environment? NDT and Ballistic Testing Life Determination Quality Sample + Statistical Performance + Aging Trends

Final Report Includes all test data, statistical analysis, and established life determination. Finalized and approved DoD reports are uploaded to official government systems. Reports available through appropriate request process. Foreign Military Sales (FMS) Worker Joint Program Office (JPO)

Ensures the safety of our Warfighters! Summary Ordnance Assessment ensures the safety and reliability of CADs and PADs Quality of test depends on the quality of the samples New automated fleet return system will give us the good sample for a great OA. Ensures the safety of our Warfighters!

T-6 Canopy Facture

F-16 ACES II Ejection Seat CKU-5 F-16 ACES II Ejection Seat Total burn time is about 0.6 secs

Questions?