Unavailable parts not a problem for metals shop

Published Feb. 24, 2007
By Senior Airman Erik Hofmeyer
379th Air Expeditionary Wing

SOUTHWEST ASIA -- Aircraft maintenance success in a deployed environment often depends on the availability of the parts and equipment needed to get aircraft back into the fight.

Oftentimes, crew chiefs look no further than 379th Expeditionary Maintenance Squadron backshops for support when aircraft parts or other machine components are not available or are no longer produced.

Aircraft structural maintenance and metals technology Airmen from the 379th EMXS Fabrication Flight routinely turn out custom parts for aircraft and other equipment no longer produced by manufacturers. This task complements their primary duty of bending and wrapping the metal that covers the aircraft of the 379th Air Expeditionary Wing.

Airmen from the 379th EMXS Aerospace Ground Equipment Flight recently came to the fabrication flight needing to replace an airflow adapter for a power unit's exhaust system.
Airman 1st Class Francisco Estrada, 379th EMXS aircraft structural maintenance journeyman, was tasked to create this rounded stainless steel part, resembling a lug nut, with different sized diameters on each end.

Airman Estrada specializes in B-1B and C-130 sheet metal; however, his training enables him to produce many non-aircraft metal parts.

"They brought us a sample of the part that is no longer made," Airman Estrada said.

He first examined the part and consulted with metals technology technicians regarding its material composition. From there, a plan was developed to create the airflow adapter by rolling stainless steel into the correct shape.

"There are many parts that are no longer procurable and don't even show up in illustrated parts breakdown anymore, but as long as we can get a sample, we can get it done," said Senior Master Sgt. Ray Boone, 379th EMXS Fabrication Flight chief.

Aircraft structural maintenance technicians here specialize in many different aircraft from across the Air Force including bombers, tankers, C-130s and fighters.

Recently, a B-1B Lancer was recently damaged by lighting while flying on a mission. The lightning entered the aircraft and exited through a wing tip, damaging the inner core of the wing tip and causing minor structural damage.

Most damage is done as lightning exits an aircraft, not when it enters, Sergeant Boone said.

The repair work for this damage was another example of improvised maintenance performed by the fabrication flight. The parts and equipment needed for to repair the wing tip are only available at the aircraft's home station, so the fabrication flight worked with on site engineers to temporarily repair the aircraft so it could be flown back to home station for maintenance.

The flight does not have blinders on, or just one method of working. It is a meld of Airmen with a wide range of experience who work together to repair aircraft with varying repair criteria, Sergeant Boone said.