1 Armament Directorate USAF Items of Interest Tim CulbertsonProgram Manager AFLCMC/EBHJ Munitions Sustainment Division Hill Air Force Base, Utah (801) /DSN: FINAL Approved: Case Number 75ABW Approved for Public Release. Distribution Statement A: distribution unlimited

2 Overview ACES II Ejection Seat Components F-15 ComponentsJAU-8 Ejection Initiator Drogue Gun Cartridge CKU-5 Rocket Catapult Trajectory Divergence Rocket Motor (TDRM) Reefing Line & Locking Cord Cutters Digital Recovery Sequencer (DRS) Time Compliance Technical Order (TCTO) Modern ACES Seat Sequencer (MASS) TCTO F-15 Components Canopy Remover Cartridge F-16 Components Canopy Jettison Rocket Motor (CJRM) Emergency Canopy Release Line (ECRL) M99 Initiator Detonation Transfer Assembly (DTA) F-4 Thermal Battery FINAL Approved: Case Number 75ABW Approved for Public Release. Distribution Statement A: distribution unlimited

3 ACES II JAU-8 Ejection InitiatorIssue: Production delays on three (3) contracts; components late to need Cause: Administrative lead times and processes delayed contract award and replacement component deliveries by 13 months Delays in acquiring hardware from supplier Impact: Temporary life extensions supportable up to 24 months beyond original expiration to accommodate delivery of replacement components and installation Get Well: Work Order M758N2193; 1,073ea Original scheduled delivery January 2015 Shipped in-place awaiting shipping instructions August 2016 Work Order M758N4301; 1,212ea Original scheduled delivery 30 April 2017; now 30 September 2017 Work Order M758N5320; 415ea Original scheduled delivery 31 October 2017; now 31 May 2018 PR ; 887ea – Estimate contract award by 30 September 2017 PR ; 858ea – Estimate contract award by 30 September 2018 FINAL Approved: Case Number 75ABW Approved for Public Release. Distribution Statement A: distribution unlimited

4 ACES II Drogue Gun CartridgeIssue: Contract delivery of replacement components late to need Cause: Administrative lead times and processes affecting FY13 and FY14 procurement packages and Military Inter-agency Purchase Requests (MIPR) delayed contract awards by 13 months Production line transferred from Hi-Shear (Torrance, CA) to Chemring Energetic Devices (Downers Grove, IL) – Required First Article Test (FAT) for qualification FAT failure and investigation April 2017 Impact: Temporary life extensions supportable up to 24 months beyond original expiration to accommodate delivery of replacement components and installation Get-well plan: Contract N CK072; 1,764ea Anticipate delivery of 1,366ea by 12 Jul 2017 Anticipate delivery of 398ea by 30 Nov 2017 PR ; 943ea - Estimate contract award by 30 September 2017 FINAL Approved: Case Number 75ABW Approved for Public Release. Distribution Statement A: distribution unlimited

5 ACES II CKU-5 Catapult Issue: Cause: Impact: Get Well:Contract delivery of replacement components late to need Cause: Administrative lead times and processes affecting FY14 and FY15 procurement packages and Military Inter-agency Purchase Requests (MIPR) delayed contract awards by 13 months and 12 months respectively Lot Acceptance Test (LAT) failures; de-certification of digital x-ray equipment (damaged detector), and need for submission/approval of many waiver requests Impact: Temporary life extensions supportable up to 24 months beyond original expiration to accommodate delivery of replacement components and installation Get Well: Contract N CK108; 869ea Original scheduled delivery October 2012 Shipped complete August 2016 awaiting shipping instructions Contract N CK109; 867ea Lot 1 (280ea) original scheduled shipment March 2017; now June 2017 Lot 2 (295ea) original scheduled shipment June 2017; now August 2017 Lot 3 (292ea) original scheduled shipment September 2017; now December 2017 Contract N C-K043; 286ea Delivery scheduled for June 2018 PR ; 221ea - Estimate contract award by 30 September 2017 FINAL Approved: Case Number 75ABW Approved for Public Release. Distribution Statement A: distribution unlimited

6 ACES II Trajectory Divergence Rocket MotorIssue: No contract in-place to deliver replacement components since 2012 Cause: Original contracted manufacturer became unqualified after initial contract award Follow-on contract award delayed 36+ months due to administrative processes and errors with purchase requests (consolidated buy). Four (4) years worth of requirements (FY13-FY16) Impact: Temporary life extensions supportable up to 18 months (NTI and TAC lots) and 24 months (UPC lots) beyond original expiration to accommodate delivery of replacement components and installation Get Well: Contract N C-K048 AWARDED 26 April 2017; 913ea Deliveries August through November 2018 PR FD ; 111ea Incorporated as a procurement option on N C-K048 Option to be initiated by 31 May 2017 Estimated delivery is December 2018 FINAL Approved: Case Number 75ABW Approved for Public Release. Distribution Statement A: distribution unlimited

7 ACES II Parachute Reefing Line and Survival Kit Locking Cord CuttersIssue: Multiple delinquent contracts; Sole Source manufacturer unresponsive Cause: Non-availability of M42 Primers; explosive mishap and investigation; production capacity limitations; competing commercial contract priorities; production backlog Impact: Temporary life extensions supportable up to 24 months beyond original expiration to accommodate delivery of replacement components and installation Get Well: Reefing Line Cutters: Contract N C-K060; 898ea Original scheduled delivery September 2014; now 31 May 2017 Contract N M-K038; 185ea Original scheduled delivery March 2016; now 31 May 2017 Contract N C-K087; 533ea Original scheduled delivery January 2017; now TBD Contract N M-K055;584ea Original scheduled delivery August 2017; now TBD FINAL Approved: Case Number 75ABW Approved for Public Release. Distribution Statement A: distribution unlimited

8 ACES II Parachute Reefing Line and Survival Kit Locking Cord CuttersContract N C-K040; 556ea Original scheduled delivery January 2015; Completed shipping process March 2017 Contract N C-K029; 506ea Original scheduled delivery October 2015; Began shipping process April 2017 Contract N M-K086; 403ea Original scheduled delivery September 2016; now TBD Contract N C-K063; 371ea Original scheduled delivery March 2017; now TBD DCMA investigating production status Qualify second source manufacturer by September 2018 Solicitation to be released by June 2017 Source Selection/Contract award by Sep 2017 PR (Reefing Line Cutters); 519ea PR (Locking Cord Cutters); 636ea FINAL Approved: Case Number 75ABW Approved for Public Release. Distribution Statement A: distribution unlimited

9 ACES II Digital Recovery Sequencer (DRS) Shorting Plug TCTOIssue: Pilot ejected and digital recovery sequencer failed to perform automatic operations Pilot pulled emergency manual parachute deployment handle for seat man separation and parachute deployment Cause: Channel 1 failed due to defective Power-On reset chip Channel 3 failed due to firmware bug and noise Impact: All fielded DRS units are affected by firmware and hardware issues that directly contributed to this failure ~8,000 aircraft DRS system reliability requirement is 0.999, 90% confidence; currently 0.056% observed failure rate – Risk Assessment “I-E” Get Well: Test port shorting plug qualified to mitigate failures - July 2015 Time Compliance Technical Order (TCTO) published January 2016 Requires TCTO compliance at 36-month seat inspection TCTO Kit provided at no cost for DRS procured via FMS Cases with US Government Shipments began 12 January 2016 and completed 7 September 2016 DRS procured with seat/aircraft delivery – Submit SDR against contract DRS to be replaced by the Modernized ACES Seat Sequencer (MASS) through attrition at DRS service life expiration FINAL Approved: Case Number 75ABW Approved for Public Release. Distribution Statement A: distribution unlimited

10 ACES II Digital Recovery Sequencer (DRS) Shorting Plug TCTOFINAL Approved: Case Number 75ABW Approved for Public Release. Distribution Statement A: distribution unlimited

11 ACES II Modernized ACES Seat Sequencer (MASS) TCTOIssue: HQ ACC identified requirement to replace environmental sensor on ACES II Ejection Seat (12 July 2009) - Environmental sensor and TTU-415/E tester are inconsistent USAF Safety Center recommendation from 2012 mishap to “replace environmental sensor and current recovery sequencer with a more reliable component to optimize the probability of correct ejection mode selection.” MASS will replace the Digital Recovery Sequencers (DRS) by attrition via TCTO Replaces environmental sensor with Pressure Transmission System (PTS) Impact: Improved ejection mode determination; eliminates need for TTU-415/E Test Set Get-well plan: Qualification completed March 2015 Airworthiness certification complete for F-16; Anticipate F-15 certification by 15 May 2017 13A Technical Order and TCTO procedures validated August 2016 To be released upon F-15 Airworthiness certification; ~30 June 2017 Contract FA C-0018; 220ea – Shipped in-place April 2016 Contract FA C-0042; 283ea – Shipped in-place August 2016 Contract FA C-0002; 106ea – Anticipate delivery by 31 July 2017 PR FD ; 1,150ea – Anticipate contract award by 15 May 2017 PR FD ; 469ea - Anticipate contract award by 30 September 2017 FINAL Approved: Case Number 75ABW Approved for Public Release. Distribution Statement A: distribution unlimited

12 ACES II Modernized ACES Seat Sequencer (MASS) TCTOPressure Transmission System (PTS) PTS and MASS installed in ACES II seat Analog Sensor Pressure Transmission System FINAL Approved: Case Number 75ABW Approved for Public Release. Distribution Statement A: distribution unlimited

13 F-15 Canopy Remover CartridgeIssue: HES propellant experienced production halt by industry (ATK & BAE) USG struggled to produce a useable quantity of propellant Contract Required Delivery Date (Original): Sep 2012 FA C-0048 (4 years of requirements) awarded 10 June 2016 Initial contract award delays due to non-availability of propellant Lot Acceptance Test (LAT) failure on 17 December 2016 Low thrust pressure on the 4th of 10 test articles (-65°F shot) First three (3) shots were from two (2)-ambient (~70°F) and one (1)-hot (+200°F) test articles, both of which passed specification requirements UTAS in coordination with CAD/PAD JPO and The Boeing Company (Specification Owner), immediately suspended LAT and initiated investigation actions to determine/identify root cause(s). This action is ongoing, but initial investigation has outlined the following actions: Completed tear down of Canopy Remover to determine any anomalies/failure modes– Negative Completed tear down of remaining Canopy Remover Cartridges and tested propellant properties to determine any anomalies/failure modes – Negative Reload Canopy Remover Cartridges (alter propellant amounts as necessary) and perform load-sizing shots to optimize performance of the canopy remover Reload remaining Canopy Remover Cartridges with accepted sizing shot results – In Progress Resume LAT by mid March 2017 – Lot 1 passed 22 March 2017 FINAL Approved: Case Number 75ABW Approved for Public Release. Distribution Statement A: distribution unlimited

14 F-15 Canopy Remover CartridgeImpact: Warfighters flying at risk on temporary life extensions supportable up to 4 years beyond original expiration F-15 Program Office Operational Risk Assessment (Medium Risk), dated 16 July 2016 69 FMS single seat F-15 A/C; 85 FMS dual seat F-15 B/D are on temporary life extensions Get Well: Contract FA C-0048 awarded - 10 Jun 2016 Four (4) successful propellant mixes produced – Aug 2016 Complete mechanistic aging assessment through ATK – Aug 2017 Contract delivery April 2017 through September 2018 Lot 1 deliveries complete 12 Apr 17 Lot 2 LAT scheduled for 19 May 17 FINAL Approved: Case Number 75ABW Approved for Public Release. Distribution Statement A: distribution unlimited

15 F-15 Canopy Remover CartridgeFINAL Approved: Case Number 75ABW Approved for Public Release. Distribution Statement A: distribution unlimited

16 Resolved with production now underwayF-16 Canopy Jettison Rocket Motor Issue: Three ruptured motor failures since 2010 at United Technologies Aerospace Systems (UTAS) Lot Acceptance Test (LAT) failure 9 Aug 2010 Cold unit (-65°F) experienced rapid overpressure (exploded) Batch check unit failure 9 Mar 2012 Hot unit (+200°F) experienced rapid overpressure (exploded) LAT failure 28 Oct 2013 160 of 290 grams recovered  Resolved with production now underway FINAL Approved: Case Number 75ABW Approved for Public Release. Distribution Statement A: distribution unlimited

17 F-16 Canopy Release Rocket MotorCause: (UTAS) Insufficient bond strength between propellant, liner, and motor tube case leading to excessive surface area burning and unit overpressure (Nammo Talley) Propellant grains (PN 55012) cast from TAL-1526 B161 propellant exhibited soft propellant at the machined ends of the grain. The soft propellant exhibited inadequate material strength and was deformable with light hand pressure Impact: Temporary life extensions supportable up to 24 months (NTI and TAC lots) and 48 months (UPC lots) beyond original expiration to accommodate delivery of replacement components F-16 A/B/C/D Fleet (USAF aircraft and partner countries) Low risk (Catastrophic/Improbable, I-E) Product recalled Get Well: FA C-0003 (UTAS); 172ea L/H and 134ea R/H (Warranty Returns) 107ea shipped March – June 2016; Remaining 199ea to ship by 31 May 2017 FA C-0004 (Nammo Talley); 155ea L/H and 154ea R/H Original scheduled delivery December 2016; now September 2017 FA C-0054; 88ea L/H and 70ea R/H (Nammo Talley) Original scheduled delivery May 2017; now October 2017 PR ; 160 L/H and 245 R/H – Anticipate contract award by 30 June 2017 FINAL Approved: Case Number 75ABW Approved for Public Release. Distribution Statement A: distribution unlimited

18 F-16 Emergency Canopy Release LineIssue: Contract delivery of replacement components late to need Cause: First Article Test (FAT) successful Fit checks conducted three times before “successful” fit approved Production tooling changed by PSEMC after approved fit check without knowledge or approval of USG Dimensional verification not conducted correctly by PSEMC on production ECRLs prior to delivery of Lot Numbers MSV13L and MSV14F Impact: 161 ECRLs (P/N: ) delivered to partner countries do not fit in aircraft Suspended from issue/use – directed to submit Supply Discrepancy Reports (SDR) F-16 A/C Fleet (USAF aircraft and partner countries) Get Well: Three new reworked ECRLs provided to government for fit check Jul One of three acceptable Non-compliant ECRLs re-bent for fit check Sep Still not acceptable PSEMC in-process of bending new fit check golden units to meet LM specification - 31 May 2017 PSEMC to upgrade tooling and bend fixture to prove repeatable process – June 2017 PSEMC & USG to conduct fit check – June/July 2017 PSEMC to rebuild and replace by September 2017 FINAL Approved: Case Number 75ABW Approved for Public Release. Distribution Statement A: distribution unlimited

19 Detonation Transfer Assembly (DTA)Issue: Obsolescence of Halar 300 (Plastic beads used in DTA thin layer explosive cord) United Technologies Aerospace Systems (UTAS) notified by supplier they no longer produce small runs of Halar 300 March 2012, UTAS submitted Engineering Change Proposal (ECP) indicating Halar 300 was obsolete & replacement material was Halar 300LC (Low Corrosive) US Government required Halar 300LC meet all F-16 specifications for DTA performance and shelf/service life UTAS did not provide adequate testing to prove the material would age to meet the assigned shelf/service life of DTA lines US Government rejected Engineering Change Proposal (ECP) CAD/PAD Joint Program Office asked Halar 300 supplier to determine if a large procurement was possible Contract awarded for production run of 26,400 pounds; shipped 2013 New contract negotiated with UTAS to extrude Halar 300 plastic into explosive cord with stainless steel over-braid Stocked at UTAS and provided as government furnished material (GFM) to be manufactured into DTA lines – 2014 Production resumed with increased operators and production shifts to meet backlog FINAL Approved: Case Number 75ABW Approved for Public Release. Distribution Statement A: distribution unlimited

20 Detonation Transfer Assembly (DTA)Product Recall/Suspension #1 – February 2015 Three production shifts implemented to fill backlog once GFM braided cord was available (~1,000 lines/month) Production engineer identified new operator did not cut sufficient material from rejected sections & splices Automated inspection equipment sprays red mark on areas with high or low explosive core load; 80” sections to be removed Affected lines produced/delivered in 2014 are restricted from issue and currently pending warranty replacements FINAL Approved: Case Number 75ABW Approved for Public Release. Distribution Statement A: distribution unlimited

21 Detonation Transfer Assembly (DTA)Lot Acceptance Test (LAT) Failure – December 2014 During routine LAT a single line failed to propagate Initial investigation reviewed many possible factors but pointed to test fixture causing line kinking Fixture modified with new “Z” bend fitting and double sampling added; additional failures occurred Extensive explosive core load measurements revealed some lines were very low FINAL Approved: Case Number 75ABW Approved for Public Release. Distribution Statement A: distribution unlimited

22 Detonation Transfer Assembly (DTA)Product Recall/Suspension #2 – June 2016 Investigation identified all 2014 and 2015 produced DTA lines as suspect and recall issued Suspension from issue released for affected lines Low/high core loads due to improper laser core load sensing system calibration (Root Cause) 73 USAF F-16 aircraft affected with one or more recalled lines installed Hazard Risk Assessment completed (Catastrophic/Improbable, I-E) Production halted pending manufacturing process improvements Trial process runs initiated to validate updated procedures & testing First Article Test (FAT) imposed for manufacturer to re-qualify production capability Impact: Production resumed March 2017 after manufacturing process improvements & successful FAT B-2, F-16, and T-6 aircraft Temporary life extensions supportable up to 72 months beyond original expiration to accommodate delivery of replacement components Multiple delinquent Contracts/Delivery Orders (DO) FA C-0076 (F-16) = 4,399ea FA D-0002 (F-16) = 8,904ea N C-K014 (B-2) = 6 Kits (618ea individual lines) N C-0010 (T-6) = FINAL Approved: Case Number 75ABW Approved for Public Release. Distribution Statement A: distribution unlimited

23 Detonation Transfer Assembly (DTA)Closure Plan: Baseline Current Core load failure investigation/improved inspection & process procedures Oct 2016 Trial process runs to validate updated procedures Nov 2016 First Article Test (FAT) – Several lines vented/one severed Mar 2017 Coordinate w/ B-2, F-16, B-1 SPO for concurrence/risk acceptability Mar 2017 Lot Acceptance Test (LAT) B-2; 2 of 8 Kits Mar 2017 F-16; -721 & -723 Lines (1,289ea of 2,588ea) May 2017 QF-16; 10 of 73 Kits May 2017 T-6; 120 of 4,440 lines Jun 2017 Return to production at initial rate of ~1,000/month Mar 2017 ~31,000+ DTA lines on backlog (USAF/FMS, Navy, Commercial) Production delivery Apr 17 – Oct 18 Award 5-Year IDIQ Contract Feb Jun 2017 FINAL Approved: Case Number 75ABW Approved for Public Release. Distribution Statement A: distribution unlimited

24 F-16/OA-10/OV-10 M99 InitiatorIssue: Contract delivery of replacement components late to need Cause: Production delayed due to Production delayed due to foreign material detected in primers during x-ray inspection Primer is internal component to M91 Impulse Cartridge installed into the M99 Initiator Loose primer composition is classified as critical defect (due to unknown aging characteristics) Impact: Temporary life extensions supportable up to 23 months beyond original expiration to accommodate delivery of replacement components and installation F-16, OA-10, and OV-10 Fleet (USAF aircraft and partner countries) Get Well: N M-K076; 160ea - estimated ship date October 2017 N C-K132; 264ea - estimated ship date December 2017 N C-K068; 63ea – estimated ship date April 2018 Work Order M218C6214; 174ea - GFM delivery due June 2018 FINAL Approved: Case Number 75ABW Approved for Public Release. Distribution Statement A: distribution unlimited

25 F-5/OA-10/T-38 M26 Initiator Issue: Cause: Impact: Get Well:Contract delivery of replacement components late to need Cause: Lot Acceptance Test (LAT) failure due to time to maximum pressure Production delayed due to investigation initiated after production line shut down Oct 2016 after near miss incident involving M90 delay cartridge M90 Delay cartridge is internal component to M26 Initiator Production resumed January 2017 Impact: Temporary life extensions supportable up to 36 months beyond original expiration to accommodate delivery of replacement components and installation F-5, OA-10, and T-38 Fleet (USAF aircraft and partner countries) Get Well: N C-K059; 36ea - estimated ship date March 2018 Work Order M207C6069; 77ea - GFM delivery due May 2017 FINAL Approved: Case Number 75ABW Approved for Public Release. Distribution Statement A: distribution unlimited

26 F-4 Thermal Battery Issue: Cause: Impact:Sole Source Manufacturer, Rafael Advanced Defense Systems, has shut down the Thermal Battery production line Will only resume production for procurements with a minimum order of 400ea Cause: Current combined FMS FY16/FY17 requirements total 175ea No substitute batteries that can fulfill this requirement Impact: Temporary life extensions are no longer recommended for installed thermal batteries F-4 Fleet (partner countries only) Second Source Qualification Efforts: Several companies are interested (Eagle Picher & Diehl) Requires full FMS funding of ~$800K (no USAF requirements) Would take ~3 years to qualify a second source Remaining life of F-4 fleet does not make this effort economical – No interest from users FINAL Approved: Case Number 75ABW Approved for Public Release. Distribution Statement A: distribution unlimited

27 QUESTIONS ? FINAL Approved: Case Number 75ABW Approved for Public Release. Distribution Statement A: distribution unlimited