Aviation composite course saves money, lives

By Carlotta Maneice, AMRDEC Public AffairsJanuary 26, 2015

Aviation composite course saves money, lives
1 / 3 Show Caption + Hide Caption – (Photo Credit: U.S. Army) VIEW ORIGINAL
Aviation composite course saves money, lives
2 / 3 Show Caption + Hide Caption – (Photo Credit: U.S. Army) VIEW ORIGINAL
PIF Composite Lab Panel
3 / 3 Show Caption + Hide Caption – (Photo Credit: U.S. Army) VIEW ORIGINAL

REDSTONE ARSENAL, Ala. (Jan. 23, 2015) -- Components made from advanced composite materials are becoming more common on Army aircraft due to their increased strength, reduced weight and reduced lifecycle costs.

U.S. Army Aviation and Missile Research, Development and Engineering Center, or AMRDEC, is the head of composite repair in Army aviation through its Prototype Integration Facility, or PIF. Ten Soldiers, from the 1108th Theater Aviation Sustainment Maintenance Group, Mississippi National Guard, attended the Basic Repair Course, here, Jan. 12-16.

"The biggest difference we have made to the warfighter is developing an Army capability in advanced composites that allows the maintainers to repair structures made of advanced composite materials such as carbon fiber, fiberglass, and aramid (Kevlar)," said Kimberly Cockrell, advanced composites lab lead.

"Having advanced composites in primary flight structure is new to the Army, and Soldiers did not have the appropriate skills to repair these components," said Earl Thomas, lead composite instructor. "The PIF was able to design and validate the repair process, and then train the Soldiers to be able to accomplish those repairs."

The repair course offers an overview of the materials, processes, and tools used to repair advanced composites. Although the class is based on the published procedures for the UH-60M helicopter's horizontal stabilator, the processes taught to the Soldiers are applicable across all aviation platforms.

"This class has taught me all the necessary skills I need to work on damaged composite components," said Spc. Katelyn Turner. "This is great because with our upcoming deployment, we now have the proper training to perform airworthy composite repairs."

Over the past two and a half years, the PIF has trained more than 250 Soldiers and civilians in advanced composite repair processes and other composite fundamentals. The PIF offers three different courses, is comprised of classroom lectures and practical hands-on exercises: Advanced Composite Repair (40 hours), Technical Inspection of Advanced Composite Repairs (24 hours) and Fundamentals of Composites (40 hours).

"Writing and training the work procedures that enable the warfighters to keep their weapons platforms in the fight is just the start," Cockrell said. "We are also designing, fabricating, integrating, fielding and repairing components made from these materials."

In the past year, the PIF used advanced composites to save more than $40 million for the Utility Helicopters Project Management Office alone. In February 2014, the PIF was awarded the Army Aviation Association of America Material Readiness Award for accelerating the Army's widespread adoption of composites and enabling the warfighter to support those composites.

The AMRDEC PIF continues to have a direct and profound effect on Army aviation and its experience and partnerships make it the hub of Army aviation activities for advanced composites, Cockrell said.

The PIF is a subordinate unit of the Engineering Directorate which plans, develops, manages, and conducts Aviation and Missile Life Cycle Management Command programs in the areas of total life cycle systems engineering, product assurance, test, and evaluation.

---

The Aviation and Missile Research, Development and Engineering Center is part of the U.S. Army Research, Development and Engineering Command, which has the mission to develop technology and engineering solutions for America's Soldiers.

RDECOM is a major subordinate command of the U.S. Army Materiel Command. AMC is the Army's premier provider of materiel readiness -- technology, acquisition support, materiel development, logistics power projection, and sustainment -- to the total force, across the spectrum of joint military operations. If a Soldier shoots it, drives it, flies it, wears it, eats it or communicates with it, AMC provides it.

Related Links:

Army Technology Live

U.S. Army Material Command

U.S. Army Research, Development and Engineering Command

Army.mil: Science and Technology News