RCC Tool Assures Aircraft Material Integrity and Performance

  • Published
  • By Heyward Burnette
  • Materials & Manufacturing Directorate
WRIGHT-PATTERSON AIR FORCE BASE, Ohio --  Working with industry partners, AFRL developed and effectively demonstrated the "R-Card Characterization" (RCC) tool, a ruggedized handheld nondestructive evaluation (NDE) technology. The tool collects real-time measurements indicating the electrical properties of specialty materials covered by the protective exterior coating of advanced military aircraft and thus not readily accessible for inspection. By enabling this verification activity, the RCC tool helps to identify what maintenance actions and/or repairs may be necessary for restoring aircraft characteristics to the range of established limits. The new tool outperforms the Air Force's (AF) existing, antiquated system and is a viable replacement for the technology currently used to inspect advanced aircraft materials. Its small size and portability promote easy deployment and flight line utilization, features of benefit in an operational support environment.

AFRL developed the RCC NDE device to replace the Special Test Equipment (STE) Mini Probe currently in use by the AF. In addition to approaching the design effort as a chance to address known deficiencies of the STE Mini Probe, scientists also leveraged it as an opportunity to insert new technology. Their design approach produced a result that is rugged; reliable; maintainable (including easily replaced, disposable components where wear and tear is expected); and easy to manufacture.

The RCC tool is composed of two major subsystems: the probe unit and the processor unit. The probe unit contains the radio frequency circuitry needed both to generate the electrical field and to measure the signal properties received from the electrical circuit created with the specialty material. The probe unit also provides the electronics required for converting measurements from analog to digital. Meanwhile, the processor unit first receives collected measurements from the probe unit and then determines reflection coefficients and calculates resistance and reactance values. Powered by three D-cell batteries, the new RCC NDE tool is completely self-contained and fully supportable in a flight line operation. The successful transition of this technology supports the warfighter through improved maintenance practices and enhanced mission preparedness.