Project Number: A3007

Project Title: Alternative Permanent Fastener Removal

Period of Performance: SEP24 – SEP26

Removing permanent fasteners from aircraft is a necessary, yet time consuming requirement that often results in damage to the surrounding structure. Lockheed Martin Materials & Process (LM M&P) and Joint Program Office (JPO) have recently qualified an Electric Discharge Drill (EDM fastener removal system) to aid in the removal of permanently installed fasteners on limited composite substrates with special permission required each time. The system is a portable Electrical Discharge Machining (EDM). Gaps still exist for process development and impact assessment on composite and metallic substrates due to lack of standardized procedure in the event EDM fastener removal system is misaligned during operation. While the EDM fastener removal system is authorized for use in production to support a Material Review Board (MRB) task, it requires assistance from engineering in each instance. The system has yet to be used extensively within a sustainment environment due to variability of operators to repeatably use the system on-aircraft. This technology is best suited to benefit sustainment where a significant number of permanent fasteners may be removed during maintenance and modifications. Challenges exist with highly contoured areas, having accurate offset/alignment tools, and utilizing on horizontal/inverted scenarios.

This project is expected to result in a 5-year ROI of 2.84.

The Alternative Permanent Fastener Removal Advancement is expected to be implemented at Lockheed Martin Aeronautics facility during the Q2 of FY26.