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

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

3. 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

4. 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

5. 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 new OAs yearly

6. 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

7. 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

8. 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

9. 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

10. 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

11. 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

12. 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)

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

14. 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

15. 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

16. 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)

17. 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!

18. T-6 Canopy Facture

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

20. Questions?