ENJJPT SC #68T-38 Programs

Mr. Greg BrownDeputy Branch ChiefMAPA BranchSeptember 2014

T-38 Life Extension

• Current AETC retirement date 2023-2029– Follow AETC Drawdown plan

• Structure is primary concern with T-38 retirement extension– Structural modifications and inspections required

• Diminishing Manufacturing Sources and Material Shortages is a significant concern – impact unknown today

• Retirement extensions can be managed and risks mitigated with proper lead times

SC68 Funding Timeline (FY)Summary

Cost subject to changeNumbers may not add correctly due to rounding 3

  FY11 FY12 FY13 FY14 FY15 FY16 FY17 FY18 FY19 FY20 FY21 FY22 FY23 SC68 SC67 SC66Quantities: PC III Kits 9 12 6 10 10 10 9 66 47 47PC III Installs 9 9 9 10 10 10 9 57 47 47VDTS Installs 8 22 31 42 21 124 124 124ADS-B Kits 123 123 124 124ADS-B Installs 41 41 41 123 124 124AvCI Parts HUD 15 62 46 MDP 15 62 46 VOR-ILS-RCVR 18 18 18 18 18 18 15 VHF COMM 18 18 18 18 18 18 15 EED 54 Costs: PCIII $3.6 $5.1 $12.3 $13.9 $13.9 $15.0 $14.6 $11.0 $9.9 $99.3 70.8 70.8VDTS $0.2 $0.7 $0.8 $0.5 $0.6 $2.8 3.4 3.4ADS-B $1.8 $0.8 $0.8 $0.8 $4.2 4.2 4.2

AvCI $0.7 $9.1 $30.5 $23.2 $0.8 $0.8 $0.3 $65.4

Total Costs ($M) $3.8 $5.8 $0.8 $0.5 $12.9 $15.7 $15.4 $24.9 $45.9 $34.2 $10.7 $0.8 $0.3 $171.7 $78.4 $78.4

Pacer Classic III (PCIII)

Program Objectives• Ensure structural integrity of 125 aircraft at high risk of

grounding prior to FY20• Ensure execution of AETC mission through FY26

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PCIII Program Overview

NGTS PartsDLA Parts

- Parts Replaced All The Time (100% Parts) - Parts Replaced as required, Select Structural Components (SSC) - Parts Removed for Access and also SSC - Parts Removed for Access to other parts, but not replaced (RFOM)

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Pacer Classic III Way Ahead

• AETC updated retirement date to 2023-2029 – Potential increase of PCIII aircraft (additional 19 Sheppard a/c = $28.5M)– Recommend FY18/19 wedge for kit procurement and FY19/20 for installs – Requirement validation occurs during the first year of PCIII installs

• Actual structural health assessment for the high-time airframes• Destructive testing on replaced components• Further assess need for more comprehensive/intrusive inspections• Validate ASIP analysis of structural health and then make informed

adjustments

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SC68 Funding TimelineT-38C PC III

• Costs will be reconciled with individual country cost at the end of eachmodification period

•Aircraft quantities and costs subject to change

Numbers may not add correctly due to rounding

FY11 FY12 FY13 FY14 FY15 FY16 FY17 FY18 FY19 FY20 FY21 Total

Quantities:

Kits 9 12 6 10 10 10 9 66

Installs 9 9 9 10 10 10 9 66

Costs:

Kits $3.6 $5.1 $2.4 $4.0 $4.0 $4.0 $3.6 $26.7

Installs $9.9 $9.9 $9.9 $11.0 $11.0 $11.0 $9.9 $72.6

Total $3.6 $5.1 $12.3 $13.9 $13.9 $15.0 $14.6 $11.0 $9.9 $99.3

Non-US Cost Estimated $2.7 $1.1 $3.1 $3.5 $3.5 $3.8 $3.7 $2.8 $2.5 $26.5

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VDTS/SBIS Program

• Video Data Transfer System (VDTS)– Replaces current obsolete video tape recorder

• Used for debriefing both SUPT and IFF students• Especially important on IFF missions for critiquing

energy management and validating weapons employment– Kits already purchased under Avionics Upgrade Program– Depot-level install

• Speed Brake Indicator Switch (SBIS)– Inadvertent speed brake actuation common in T-38

• Caused Class A mishap resulting in loss of aircraft• SBIS provides a “hands-off” means of confirming safety of the aircraft during a

critical phase of flight

– Kits already purchased; installed in conjunction with VDTS

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SC68 Funding TimelineT-38C VDTS/SBIS

Numbers may not add correctly due to rounding

• Installations began June 2011• Costs paid by US. All costs will be reconciled with individual country cost at the

end of the modification• Costs subject to change

  FY11 FY12 FY13 FY14 FY15 TotalQuantities: Kits Installs 8 22 31 42 21 124 Costs ($M): Kits Installs $0.17 $0.68 $0.84 $0.53 $0.57 $2.8Total   $0.17 $0.68 $0.84 $0.53 $0.57 $2.8Non-US Cost Estimated $0.04 $0.17 $0.21 $0.13 $0.14 $0.70

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New T-38 Modification Efforts

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T-38C AvionicsComponent Integration (AvCI)

• T-38C requires replacement of key Avionics components due to obsolescence

• Primary components affected– Heads-up Display (HUD)– Mission Display Processor (MDP)– Electronic Engine Display (EED)– VHF Comm Radios

• Notional FY16 – FY23 development and integration schedule– Development begins in FY16– Production and installs begin in FY17 for some components

• Source selection in progress– Estimated award in Q4 FY15– Costs and schedule are estimates; will revise figures after contract award

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SC68 FUNDING TIMELINET-38C AvCI

Still in Planning Phase; Costs and year of requirement subject to change

FY17 FY18 FY19 FY20 FY21 FY22 FY23 TotalQuantities (Parts): HUD 15 62 46 123MDP 15 62 46 123VOR-ILS-RCVR 18 18 18 18 18 18 15 123VHF COMM 18 18 18 18 18 18 15 123Electronic Engine Display 54 54Quantities (Installs): HUD 15 62 46 123MDP 15 62 46 123VOR-ILS-RCVR 18 18 18 18 18 18 15 123VHF COMM 18 18 18 18 18 18 15 123Electronic Engine Display 9 9 9 9 9 9 54Costs: HUD $4.6 $18.3 $13.8 $36.7MDP $2.9 $11.5 $8.6 $23.0VOR-ILS-RCVR $0.3 $0.3 $0.3 $0.3 $0.3 $0.3 $0.3 $2.1VHF COMM $0.4 $0.4 $0.4 $0.5 $0.5 $0.5 $2.7Electronic Engine Display $0.8 $0.8Installs $0.0 $0.0 $0.0 $0.0 $0.0Total $0.7 $9.1 $30.5 $23.2 $0.8 $0.8 $0.3 $65.4Non-US Cost Estimated $0.2 $2.3 $7.6 $5.8 $0.2 $0.2 $0.1 $16.3

Automatic Dependent Surveillance-Broadcast (ADS-B)

• FAA is transforming air traffic control to a satellite-based system known as the Next Generation Air Transportation System (NextGen)

• Mandatory for all aircraft operating in CONUS by 2020– Increases safety and efficiency

• Airspace requiring ADS-B compliance:– Class A, B, and C– Class E above 10,000 ft– Around those airports identified in 14CFR 91, Appendix D

• AETC T-38C training syllabi require access to controlled airspace above 10,000 feet

• AF 1067 approved to incorporate ADS-B in T-38s Fleet-wide• Solution to be determined as part of AvCI contract effort

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ADS- B Funding Timeline (FY)

Numbers may not add correctly due to rounding

Still in Planning Phase

FY16 FY17 FY18 FY19 FY20 TotalQuantities: Kits 123 123Installs 41 41 41 123 Costs ($M): Kits $1.8 $1.8Installs $0.8 $0.8 $0.8 $2.4Total $1.8 $0.8 $0.8 $0.8 $4.2Non-US Cost Estimated $0.5 $0.2 $0.2 $0.2 $1.1

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T-38 Anti-Skid/Brake

• Brake failures experienced starting in 1999• Two mishaps recommended T-38 antiskid system • Prototype antiskid system tested on aircraft

– Indicated successful braking ops/performance

• AETC/CC cancelled T-38 Improved Brake System Program (IBSP) in Apr 09

• Highest unmitigated risk on T-38• System Safety Evaluation

– Prevent 7-19 mishaps (2 class A mishaps) and 1 pilot death prior to 2029

• Estimated cost $50.27M – Recommend start in FY16

Still in Planning Phase15

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Fwd Canopy DevelopmentBackground : The T-38 has experienced 7 Class A mishaps and 3 pilot fatalities since 1964 due to birdstrikes to the front canopy transparency. The current T-38 front canopy has a minimum birdstrike capability of 4 lb. bird at 125 knots. USAF expects to increase the minimum birdstrike capability significantly to be consistent with mission profiles without shattering in order to significantly increase pilot safety. The Program is in the early stages of market research and feasibility testing.

Still in Planning Phase

Sustainment Efforts

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FY13 Cost Drivers

• New -33 Wings and Wing Tips – Sheppard FY13 Costs $8,424,281.70 for 5 wing sets

• New Landing Gear – Sheppard FY13 Costs $1,753,685.04 for 12 ship sets

• Fatigue Critical Locations - Additional Inspections ~157 man-hours per aircraft

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FY14 Cost Drivers

• New -33 Wings and Wing Tips – Sheppard FY14 Costs $8,424,281.70 for 5 wing sets

• New Landing Gear – Sheppard FY14 Costs $1,607,544.62 for 11 ship Sets

• Lower Center Longeron – Sheppard FY14 Costs $740,573.40 to replace 8 longerons

• Fatigue Critical Locations - Additional Inspections ~157 man-hours per aircraft

• Asbestos Removal – Sheppard FY14 Costs ~$1,915,462.00 for 42 aircraft

• Attach Lower Aft Support Cracks – LH $4,843.35 RH $4,090.35

TCTO 1T-38-837Control Rods and Magnesium Parts Replacement

TCTO 837 addresses two issues in the primary flight control system. Inspections showed that magnesium CSIs contained corrosion damage. They also showed that control rods were bent which induces fatigue damage. To correct these issues the control rods will be replaced with new control rods. To correct the corrosion on the magnesium parts, new parts will be built out of aluminum and replaced. This is a one time change out of 39 flight control parts.

Control Rods Magnesium Parts

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SC68 Funding TimelineMagnesium to Aluminum

Numbers may not add correctly due to rounding

FY13 FY14 FY15 FY16 TotalQuantities: Kits 8 42 43 31 124Installs 8 42 43 31 124 Costs ($M): Kits* $0.00 $0.00 $0.00 $0.00 $0.0Installs $0.33 $1.64 $1.97 $1.42 $5.4O&A $0.03 $0.16 $0.2 $0.14 $0.5Total $0.36 $1.81 $2.17 $1.57 $5.9Non-US Cost Estimated $0.11 $0.54 $0.65 $0.47 $1.8

* Kit cost included in the install rate

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TCTO 1T-38-870Engine Bay Asbestos Removal Effort

Asbestos originally used in the production of T-38 aircraft in the engine bays and liquid oxygen system areas as an insulator. It is now recognized asbestos poses a major health risk and field units are being tasked to perform increasing inspections in these areas due to aircraft age and usage. Removing the asbestos at depot creates a single controlled environment for asbestos removal allowing the field perform required inspections more efficiently without work-arounds required to mitigate asbestos exposure..

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Pre 870 Post 870

Asbestos Removal

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Asbestos RemovalBackground: Asbestos is used to isolate the heat shields from the aluminum structure. Asbestos is considered a carcinogenic and requires Hazmat procedures to be in place when performing maintenance in this area.

SC68 Funding TimelineAsbestos Removal Program

Numbers may not add correctly due to rounding

FY14 FY15 FY16 TotalQuantities: Kits 42 42 40 124Installs 42 42 40 124 Costs ($M): Kits* $0.00 $0.00 $0.00 $0.0Installs $1.90 $2.23 $2.48 $6.6O&A $0.19 $0.22 $0.25 $0.7Total $2.09 $2.45 $2.73 $7.3Non-US Cost Estimated $0.63 $0.73 $0.82 $2.2

* Material/Kit cost included in the install rate

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Lower Center LongeronBackground : Cracks are being discovered on lower center longerons during phase inspection. The field cannot replace or repair these longerons. The depot is currently replacing them. Both left and right longerons are replaced regardless if only one side is cracked.

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Attach Lower Aft Support

Background: Inspection added to depot workload during asbestos removal as opportunistic maintenance. Cracks were discovered on numerous aircraft in depot. An inspection TCTO will be issued to inspect all aircraft in the field.

Cost Saving Measures

• New LED Beacon Light• Increased visibility• Increased mean time between failure• First deliveries Aug 14

• New Radial Tires• Increased Landings• First deliveries Sep 14

• New Generator Stator Housing• Operates at cooler temperatures• Increased mean time between failure• Currently implemented

• Improved P-panel Circuit Cards• Currently under test and evaluation

• T-5 Amp Go No Go Tester• Capability to test T-5 Amp before returning to contractor for repair• Approximately 60% returned to supply as serviceable

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LED Beacon Light

Background: Existing electromechanical rotating beacon light is prone to failure due to age and condition. This light has a mean time between failures of <300 hours. The new LED beacon has no moving parts and is expected to have a MTBF of >27,000 hours.

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Generator Stator Housing

Background: During depot overhaul, stator housings needed to be condemned due to damage to the stator housing. A redesign was initiated and a new stacked housing was approved. Testing proved that a generator operated at cooler temperatures and service life increased. Several test generators are still in service after 1400 hours.

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Protection Panel Circuit CardsBackground: Legacy P-panel circuit cards are 1960s technology. New circuit cards use state of the art technology and are expected to increase service life. Legacy and improved p-panels can be installed on an aircraft with no issues. Operational testing is scheduled soon for final approval.

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Bias vs Radial Tires

FEATURESBENEFITS

Bias Radial

Improved FOD Resistance

Mature Technology

Low Heat Generation

Improved Ride Quality (Reduced Vibration/flat spots)

Tire Cooling Time Reduced

Less Rolling Resistance

Increased Overload & Taxi Durability

Marginal Safety Benefit

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Safety Initiatives

• Forward Canopy Redesign – Improved bird-strike resistance

• Flap Y Rod Replacement – TCTO 1T-38-875 issued Jun 14

• Rudder Interconnect Crank Replacement – Deliveries Mar 16

• Rudder Force Producer Spring Replacement – Currently implemented

• Control Stick Bolt Safety Wire – Currently Implemented

• Brake Quadrant Replacement – Deliveries Feb 15

Summary

• Cost figures presented are subject to change due to program delays, aircraft beddown changes, DoD funding adjustments, efficiencies not determined, contract restructuring and re-pricing, or other unforeseen circumstances.

• This info is provided for long range budget planning purposes and should not be interpreted as a final cost estimate.

• Our goal is to ensure NATO’s future fighter pilot training needs are met and ENJJPT, with new advanced training systems, will continue to produce the world’s best pilots.

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Recommendation

Steering Committee approve proposed funding plan

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Backup

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Escape System Upgrade Program(ESUP)

• Description– ACAT III program– Replaced legacy T-38C ejection seat, improved functionality– Effectivity: 447 T-38C aircraft– Completed final install 12 Jun 14– Program in contract closeout

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