SAFE ENGINEERING, INC.saf-engineering.com/Publications/SAFE-Aeronautica-Aerotage_SOC.pdf · Major...
Transcript of SAFE ENGINEERING, INC.saf-engineering.com/Publications/SAFE-Aeronautica-Aerotage_SOC.pdf · Major...
SAFE INC.
A Service Disabled Veteran Owned Business
[email protected] 3290 Hamal Circle
Monument, CO 80132 (719) 375-5855
Who We Are • SAFE Inc.
– Dr. Scott A. Fawaz, Professional Engineer, FAA DER
– 25 years Aerospace Engineering experience
– Highly successful Service Disabled Veteran Owned Business
– IDIQ contracts, R&D contracts, Grants and Cooperative Agreements
– James S. Burd, FAA DER
– 25 years Aerospace Engineering experience
– 14 years as FAA DER in Stress design and construction, fatigue and damage tolerance
– Provides engineering and certification services to various customers in support of in service repairs, modifications and replacements to major airframe structural components
– Brad Hardwick
– 30 years experience in avionics
– Provides innovative aircraft systems integration engineering and certification to the aerospace industry with technical avionics expertise
– Specializes in comprehensive electrical and structural design data packages for installation on both civil and military applications
What We Do • SAFE Inc.
– USAF Aircraft Structural Integrity Program (ASIP)
– Durability and Damage Tolerance Analysis • Fracture Mechanics
• Environmentally Assisted Cracking
• Classic Fatigue Analysis
– Design and Analysis of Aircraft Structure
– Computational Structural Mechanics • Finite Element Analysis
• High Performance Computing
– Design of Experiments • Static and Fatigue Test Plan Development
• Test Fixture and Specimen Design and Analysis
– Failure Modes and Effects Analysis
– Reliability and Risk Analysis
– FAA 14 CFR Part 25, Part 23 Aircraft • Static Analysis, Fatigue Analysis, Design & Construction, M&P Metallics, Damage
Tolerance Analysis, Major Repairs and Alterations
What We Do • SAFE Inc. cont.
– Software Experience
• Finite Element Analysis – MSC PATRAN/NASTRAN, ZIP3D, CRACK3D, COSMOS/M, STRIPE
• Fracture Mechanics – AFGROW, NASGRO, CRACKS2000
• CAD/CAE – SolidWorks / CATIA
• Numerical Analysis – MathCAD
• High Performance Computing – C/C++, FORTRAN, Unix/Linux, Shell Scripting, Batch Computing
• Office Automation – Microsoft Office Suite, Microsoft Project, Microsoft Publisher
What We Do • SAFE Inc. cont.
– Avionics and Systems Integration • Electrical Load Analysis
• Electrical Substantiation
• System integration design to ARINC 758 and ARINC 750 standards
• Installation Drawings and Instructions
• Assembly Orders
• ATA 100 Format System Wiring Diagrams
• Functional Hazard Assessment
• EMI Test Plan
• EWIS Analysis
• Ground Functional Test Procedures
• Airplane Flight Manual Supplement
• Instructions for Continued Airworthiness
• System Safety Analysis
• Pilot Evaluation Test Plan
• Certification Functional Test Plan
• Certification EMI-EMC Test Plan
• NVIS Evaluation Test Plan
Project Portfolio Organization
Period of
Performance Contract / Grant Number End Customer
United States Air Force Academy 09/26/2011
09/25/2015 FA7000-11-2-0011 USAFA/DFEM-CAStLE
Sabreliner Corporation 10/19/2012
07/27/2015 FA7000-10-D-0014 KC-135 Program Office
Lufthansa Technik 12/15/2012
- N/A Lufthansa Technik
L-3 Mission Integration 03/18/2013
- N/A L-3 Mission Integration
Strategic Applications International
Corp (SAIC)
02/03/2012
09/30/2012 N00178-04-D-4119, DO FG02 OuSD/AT&L
Logistics Management Institute
(LMI)
01/20/2011
09/30/2013 N/A OuSD/AT&L
Total Solutions, Inc. 07/11/2011
07/10/2012 FA7000-09-D-0022-0031 USAFA/DFEM-CAStLE
Avenger Aircraft and Services, LLC 04/25/2011
12/21/2012 N/A Various
Council for Logistics Research, Inc. 09/01/2011
09/30/2011
GS-OOF-0001P/
GST0709BG0108/PT579007
SAF/AQX Acquisition
Integration
Total Solutions, Inc. 05/26/2010
05/25/2011 FA70011-09-D-0022-0006 USAFA/DFEM-CAStLE
• Department of Defense • Avenger Aircraft and Services, LLC
• OuSD/AT&L, Corrosion Policy & Oversight
• Total Solutions, Inc.
• U.S. Air Force • Science Applications International
Corporation (SAIC)
• U.S. Air Force Academy • Logistics Management Institute (LMI)
• U.S. Navy • Sabreliner Corporation
• Lufthansa Technik
• L-3 Mission Integration
Customers
Experience
Wing Strain Analysis
ASIP and Testing
Structural Teardown & Failure
Analysis
ASIP and Structural Teardown
& Failure Analysis
ASIP
ASIP and Structural Teardown
& Failure Analysis
Wing Weep Hole Cracking
Crack Growth from Cold-
Worked Holes
Static Strength, Fatigue,
Damage Tolerance Analysis
Structural Teardown & Failure
Analysis
Static Strength, Fatigue, Damage Tolerance, Full Scale Testing
Fatigue, Damage Tolerance
Analysis of Major Modification
Experience (cont.)
Crack Growth Analyses of
Structural Repairs & Modifications
Static & Fatigue Analysis of Composite
Radome Installed on Fuselage
Full Restoration Effort: Service
Bulletins, NDT Procedures, Analysis and Design of Structural Repairs
Damage Tolerance Assessments of
Major Structural Modifications
Fatigue and Damage Tolerance
Analysis
Development of Internal Fatigue Loads,
Spectrum & Crack Growth Analysis
Service Bulletins, Damage Tolerance Assessments, Aging Aircraft Programs
Developed FAA Certification Plan,
Supplemental Structural Inspection Document (SSID), NDI Requirements
& Procedures
Fatigue and Damage Tolerance
Certification, MRB Support
MRB Support
Static & Fatigue Analysis of Composite
Radome Installed on Fuselage
Stress Analysis
Experience (cont.)
Design, Static & Fatigue Analyses of Major Repairs and Alterations
Supplemental Inspection Maintenance Program
Service Bulletins & NDT Inspection
Programs
Structural Engineering & Certification for
Major STC Installations
VIP Interior Entertainment System Auxiliary Fuel System IFE installation data package VIP Interior Cabin Lighting, Cabin Telephone, Aero H Satellite
Communication, Satellite Television, High-Speed Data/Cabin Network,
Passenger Address and Entertainment Camera
TC electrical design data package restructure, Electrical Load Analysis
Avionics Upgrade and Medical Interior
ACARS and VHF 3 Supplemental Type Certificate
- FAA Approval of Numerous Major Structural Repairs and Modifications - FAA Approval of Structural Drawings and Designs in Support Type Certification Efforts - Development and Co-ordination of FAA Certification Plans for TC and STC Projects - DER Approval of Numerous Static Strength and Damage Tolerance Analysis Reports - DER Recommend Approval of Numerous Instructions for Continued Airworthiness - Led Safety Evaluations for Service Related Issues - Provided and Successfully Obtained FAA Approval of AMOC’s
FAA DER Experience
Testing and Facilities Capabilities
• Prototype/Test Specimen Fabrication – CNC Mill (2), CNC Lathe (2), Digital Mill, Digital Lathe, Electro-Discharge
Machine (Wire and Plunge), Rapid Prototype Machine, Surface Grinder, Standard Workshop Machines and Tools
– Water Jet Cutting – Low and High Speed Saws, Wire Saw Cutter – Plasma Cutting, Tungsten and Metal Inert Gas Welders (TIG and MIG) – Autoclave, filament winder, wet/dry composite lay-up – “Heat Table” – high ∆T, ∆P
• Material Processing – High Temperature Furnace 2200°F(4) – Ultra High Temperature Furnace 3100°F, with controlled environment – Cold rolling mill – Fastener hole cold working
• Analysis and Modeling Tools – 3 supercomputers – Multiple wind tunnels
Testing and Facilities Capabilities (cont.)
• Metallographic/Fractographic – 2 Scanning Electron Microscopes (SEM), Energy Dispersion Spectrometry
(EDS), Backscatter Detectors, Electron Backscatter Diffraction (EBSD)
– Dual Beam Electron Microscope – Focused Ion Beam (FIB) Nanolab
– Atomic Force Microscope
– 4 Stereo Optical Microscopes with Digital Image Capture and Analysis
– Automated Image Analysis Equipment
– Automated Metallography Specimen Preparation Equipment: Automatic Mounting Press, Automatic Grinding and Polishing, Electro-polishing, Electrochemical and Plasma Etching
– Analytical Weighing Balance
– Enclosed flood coolant Cut off Station
Testing and Facilities Capabilities (cont.)
• Material Characterization – Macro-hardness Testers (2), micro-hardness tester, nano-indenter – Ultrasonic C-scan, Eddy Current Surface Scan (ECSS) and Eddy Current Hole
Probe (ECHP) – Differential Thermal Analyzer (DTA), Differential Scanning Calorimeter (DSC),
and Dynamic Mechanical Analyzer (DMA) – Conductivity Meter and Capacitance Meter – X-ray Diffractometer – Chemical composition/identification equipment, Quanta Desk Optical
Emission Spectroscopy – 4 Computer Controlled Potentiostats/Galvanostats for Electrochemical
Measurements – Scanning Vibrating Probe to monitor surface corrosion current – Automated Electrochemical Impedance Spectroscopy (EIS) scanning table
Testing and Facilities Capabilities (cont.)
• Mechanical Testing – Computer Controlled Mechanical Test Frames, 120 kip (1), 50 kip (1), 25
kip (5) – Computer Controlled Servo Hydraulic Test Frames (MTS Flex-Test), 220
kip (1), 110 kip (1), 55 kip (3), 22 kip (2), 11 kip (2) – Vibration shakers (2) – Thermal Environment Chamber for MTS Testing – Computer Controlled Creep testing frames with static and dynamic
loading for temperatures up to 2200°F – Salt Fog Chamber – 3-D Digital Image Correlation – Laser Doppler Vibrometer – Roll around LabView Data Acquisition and Control Carts (4)
Publications
• Archival Journal – 8
• USAF Technical Reports – 9
• Conference Proceedings - 43
References
• Dan Dunmire, Director-CPO, OuSD/AT&L
• Dr. Greg Shoales, Director-CAStLE, USAF Academy
• Sandy Reyes, Contracting Officer, USAF Academy
• Dr. Larry Butkus, Air Force Research Laboratory
• Craig Matzdorf, NAVAIR
• Dr. Robert Piascik, NASA Langley Research Center
• Patrick Safarian, Seattle ACO, FAA
• Ed Ingram, Lockheed Martin
• Prof. Richard Gangloff, University of Virginia
EVALUATIONS and AWARDS
• USAF Research and Development Engineer of the Year, 2006 (Dr. Scott A. Fawaz)
• Frank J. Seiler Research Award for Research Excellence in Engineering, USAF Academy, 2003 (Dr. Scott A. Fawaz)
[email protected] 3290 Hamal Circle
Monument, CO 80132 719.375.5855
A Service Disabled Veteran Owned Business