Project Number: A2893

Project Title: Rifled Hole Assessment

Period of Performance: SEP21 – DEC24

Currently characterization of F-35 hole quality is a subjective task utilizing legacy measurement instruments and methods. In the event of a defect, production inspectors do not have an adequate method to quickly and accurately measure and quantify defects inside a fastener hole at the aircraft to determine acceptability. Characterization of defects currently requires several steps and reviews requiring final approval away from the aircraft.  

The objective of this Center for Naval Metalworking (CNM) project is to develop and implement a handheld measurement device and inspection process which will eliminate existing inaccurate and costly inspection processes to characterize hole features, enable inspectors to quickly assess metallic and composite hole features on-aircraft, and accurately measure hole features. This project also aims to reduce costly rework by means of accurate, repeatable data so that not only are “acceptable” readings quickly defined, but the necessary amount of rework is quickly agreed upon and completed by collecting 360-degree hole surface data for external systems. Completion of this effort will result in a handheld measurement system capable of accurately and reliably measuring the entire internal surface of metallic and composite fastener holes with a tolerance threshold of 0.001” and objective of 0.0001”.  

By enabling inspectors to quickly and accurately assess metallic and composite fastener hole features on-aircraft, the proposed solution aims to reduce inspection labor hours by 10% per aircraft equating a to program lifetime savings of approximately $16.7M. 

Based on the results of testing, the team will generate the data needed for internal process verification and validation, finalize the business case analyses, and create production floor implementation plans. The transition event for this project is final performance demonstration on-aircraft. Once those activities have been successfully completed, the process will have been verified to meet the expectations of the project team, and stakeholders, and will be ready for implementation at Lockheed Martin Aeronautics. Implementation is anticipated in the third quarter of fiscal year 2025. 
 

Implementation is expected to utilize a phased approach, where the most beneficial opportunities will be assigned a higher priority and implemented first. The results of this ManTech project are expected be implemented in the production of F-35.