In a first for its manufacturing and components programs, Fleet Readiness Center Southwest (FRCSW) is creating a bulkhead for use in a multi-mission MV-22 Osprey -- and will complete it in less than two weeks.
The aircraft is assigned to Marine Medium Tiltrotor Squadron 161 (VMM-161) at Marine Corps Air Station (MCAS) Miramar.
"We were fortunate to have the material on hand when asked to do the bulkhead. Normally, when we order materials, it takes anywhere from 30 up to 120 days for delivery," said Armel Recio, manufacturing 97200 deputy program manager.
The new aluminum-alloy bulkhead replaces one that suffered severe corrosion, and is located in the aircraft's cockpit near the lower portion of the windscreen on the pilot side.
Measuring approximately 18 inches long, 3 inches wide and 2 inches high, work on the bulkhead began Dec. 7 in the 97208 shop in Building 472.
Recio said that "in the manufacturing of bulkheads, about 20 steps are involved and, if needed, may include modifications to add Request for Engineering Information (REI) or Temporary Engineering Instructions (TEI)."
"All processes were accurately performed within the given instructions and documentation," Recio said. "We had two night shift machinists who continued to work on the product until computer numerically controlled (CNC) milling was completed. No overtime was involved."
Major steps in manufacturing the process included a chemical analysis from the Materials Lab; prove out on the computer numerically controlled (CNC) HU-80 horizontal milling machine; measurements verification on the Coordinate Measuring Machine (CMM); process in the Clean Shop followed by non-destructive inspection (NDI) and quality assurance (QA).
In total, artisans from 12 fields and FRCSW teammates from the Industrial Business Office Departments, Comptrollers, as well as the Defense Logistics Agency all had a hand in the project.
"When complete, FRCSW sheet metal mechanics assigned to MCAS Miramar will install the bulkhead. Barring any unforeseen issues, installation should take about a day," Recio said.
"Before this we had only done F/A-18 bulkheads," Recio said. "There is no forecast on how many we manufacture each year. Within the last five years, we have made five similar items. The success of manufacturing this bulkhead stems from the artisans and stakeholders dedication and commitment in support of the Warfighters."