AF awards MXG Airmen for innovation

  • Published
  • By Senior Airman S.I. Fielder
  • 347th Rescue Wing Public Affairs
MOODY AIR FORCE BASE, Ga. --  The Air Force recently announced four Airmen assigned to the 347th Maintenance Group are the winners of the 2005 Exceptional Innovator Award and Air Force Productivity Excellence Award. 

Master Sgt. Carlos Fajardo, Tech. Sgt. Roy Nickel, and Staff Sgts. Sean Gunther and Joshua Duncan received the award for their work finding the Aviation Devices and Electronic Components gasket while assigned to the 347th Aircraft Maintenance Squadron’s HH-60G Pave Hawk phase dock team. 

“Just like an automobile requires service after a certain amount of miles, the HH-60 requires service after a certain amount of (flying) hours,” said Sergeant Fajardo, who was the HH-60 phase dock section chief. “Whatever a helicopter requires that keeps it down for a substantial amount of time is usually done at the phase dock.” 

The helicopter is also inspected and treated for corrosion during this time. The phase dock members saw corrosion was one of the most time-consuming services required. 

“The biggest problem is corrosion,” said Sergeant Fajardo. “These aircraft deploy to the desert a lot. Sand has a lot of corrosive properties and acts like sand paper taking the paint and coatings off.” 

Gaskets previously used in several places on the helicopter didn’t provide enough protection from water and corrosion, so the team searched for an alternative. They found it through a partnership with the Navy and Coast Guard at the Corrosion Prevention Advisory Board. 

“They approached us and asked, ‘How would you guys like to be the test bed to validate this process?’” said Senior Master Sgt. Larry Whitfield, who was the maintenance flight chief and submitted the group for the award. “At the time, AvDEC was not in the Air Force inventory.” 

After two years of cooperation with the 347th Civil Engineer Squadron Environmental Flight, the team received approval to test the new gasket on the aircraft. Small tests began on the HH-60Gs antennas; however, because of the product’s performance, the gaskets were also tested on other areas like the floor and the main gear box. 

“After six months time, we pulled it into the hangar, disassembled the whole gear box and inspected where we had the gasket,” said Sergeant Whitfield. “It was absolutely pristine.” 

After several tests at Moody, the team determined the use of AvDEC sealing products would provide corrosion protection for the mounting structure, base and connectors. The Av-DEC is designed to release polyurethane gel at the perimeter of the gasket when tightened down, which helped to simplify the process. 

“With the new gaskets there was less corrosion,” said Sergeant Duncan. “Less time and effort needed because the AvDEC kept all the water out.” 

To receive final approval, the naval air station in Jacksonville, Fla., performed a final test. CPAB chose the naval air station because of the amount of flying hours an aircraft spends over the sea, said Sergeant Whitfield. After more than 546 flying hours with more than 476 of those hours at sea, the antennas were determined to be immaculate. 

“Now, we use the gasket in different places, from the nose electronic bay component areas all the way back to the tail,” said Sergeant Whitfield. “We have AvDEC gaskets all over the helicopter.” 

The previous gaskets cost $3,300 per aircraft, while the new ones cost $1,000 per aircraft. Over a year, the new gaskets saved the Air Force more than $1 million. 

“It’s cost effective because when we took out the old component, we had to scrape and scrub the piece,” said Sergeant Fajardo. “It takes less man hours now because we don’t have to call (347th) Aircraft Structural Maintenance out there to repair the corrosion.” 

The project was an entire team effort of everyone working at the phase dock. These maintainers strive for perfection, they do what’s best for the mission and strive to make things better, said Sergeant Fajardo. 

“The team’s hard work paid off, and the gaskets provided complete base metal protection against corrosion-causing elements,” said Sergeant Whitfield. “Today, the sealants are being incorporated in nearly all gasket applications. 

“The initiative will be felt for years to come by not only the Air Force, but the Army also adopted their technique,” he added.