Market Need - Army Rotorcraft:

Army helicopters are required to operate reliably in a diverse range of extreme environments. In addition to the severely corrosive marine operating environments shown in the above slideshow, Army rotorcraft are increasingly being deployed to deserts; where sand abrasion, sand salts, extreme temperature variations, and moisture condensation create an environment that is many times more corrosive than even marine environments. Rotorcraft corrosion results in reduced operator safety and fleet readiness levels, and accounts for a substantial portion of the Army’s operations and maintenance budget. In fact, the Army’s three largest operations and maintenance cost drivers are batteries, tires, and corrosion. A 2005 study by the Office of the Secretary of Defense (OSD) estimated that the overall annual direct cost of corrosion to the Army was $3.6 billion. Of this total, $1.6 billion can be directly attributed to Army aviation and missiles. Corrosion damage to the Army’s approximately 2,450 rotorcraft accounts for the top four corrosion cost drivers and 77.8% ($1.26 billion) of the total Army aviation and missile cost of corrosion.

In addition to the significant financial impact attributed to rotorcraft corrosion damage, serious operator safety concerns exist. Between 1989 and 2000, the Army experienced 46 “mishaps,” 9 fatalities, and 13 injuries because of corrosion. As the average age of rotorcraft continues to increase, the number of corrosion related safety issues will also grow. Repairs, maintenance, and component replacement are direct costs; however, the loss of readiness, safety, and capability can be even more costly in time of a national emergency.

Often rotorcraft corrosion occurs in closed areas that are not accessible for visual inspection without partial disassembly or other labor-intensive activities. In a typical year, one Army company (B Co, 214st AVN REGT) spent 3500 man-hours for corrosion replacements. Under severe environmental conditions, the floor beams of a CH-47 rotorcraft must be inspected every 15 days. Each inspection requires partial disassembly and requires three man-days. Areas that require such an inspection schedule include: Cargo hook assemblies, Landing gear and wheel wells, Troop seat support rails, Floor panels and cargo beams, Bilge/under floor area, Ramp, Flight controls, Engine mount assemblies, and Rotor head and pitch link assemblies.

Army rotorcraft currently employ a form of Condition Based Maintenance (CBM) technology called Health and Usage Monitoring Systems (HUMS). Primitive HUMS were initially developed to improve the safety of the large twin-engine helicopters that were flown to offshore rigs in the North Sea about 30 years ago. During the last three decades HUMS technology has become more commonplace within the rotorcraft industry because of increased capabilities and reduced system costs. Despite the increased usage of HUMS; the overall effectiveness of HUMS technology is currently limited because HUMS rely on a complex network of wired sensors that is difficult and expensive to install or retrofit. Another disadvantage of the current HUMS is the additional weight associated with the complex network of wired analog sensors. Employing a wireless network of easily installable, non-destructive, digital sensors will bring HUMS to the forefront of CBM technology and allow the Army to realize all of the enterprise and operational level benefits associated with CBM technology.