US Air Force Research Laboratory (AFRL) engineers have developed new structural technologies to solve the cracking and corrosion issues related with the Lockheed Martin-built C-5 Galaxy cargo aircraft, in a bid to expand its serviceability.
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Under the Durable C-5 Structural Improvements Program, a more stress and corrosion-resistant aluminium alloy and a new die forging process has been developed to eliminate the cracks at the C-5 cargo floor’s bulkhead end fittings, which restricted its cargo carrying capabilities to a maximum of 80%.
According to the AFRL, the new procedures will help in the development of all 92 fitting shapes required for the C-5 bulkhead floor, using only two separate forging dies.
The reshaped end fittings provide an optimised design that is less prone to cracks, and also offers multiple benefits for the revamped C-5 aircraft, which includes a 25% overall cost savings, an 80% reduction in fabrication time, and a 60% increase in service life of the fittings.
A number of C-5 Galaxy aircraft were recently equipped with the new structural fittings at the Warner Robins Air Logistics Center in Georgia, US.
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By GlobalDataThe traditional methods employed earlier for repairing proved to be insufficient, as the replacement fittings provided to the aircraft often cracked during the machining process, and also had a shorter lifespan than the original parts.
The AFRL is also planning to apply the forging process to other aircraft that experience similar cracking problems.
The C-5 Galaxy is a large military transport aircraft built with a heavy intercontinental-range strategic airlift capability, to carry oversize cargos, including all 100% air-certifiable cargo.
Since 1970, the airlifter served as the global direct delivery weapons system for the US.
Image: The C-5 Galaxy is equipped with new structural fittings to increase its cargo carrying capability. Photo: courtesy of AFRL.
