MacDill "Fab" Flight: Keeping the KC-135 tankers flying

  • Published
  • By Senior Airman Tania Reid
  • 6th Air Mobility Wing Public Affairs
MACDILL AFB, Fla. --  "You break it, we mend it" is a term common to the members at the 6th Maintenance Squadron's Fabrication Flight here at MacDill.

The flight of more than 40 Airmen at Hangar 3 divided into the Structural Maintenance, Metals Technology and Non-Destructive Inspection help to repair and maintain various parts of the KC-135 Stratotankers on the base.

"There's no structure or part required to keep the KC- 135 Stratotankers flying that we can't make," said Senior Master Sgt. David Loop, 6 MXS fabrication flight chief. "Given the time and manpower to get the job done our team will do it. We help with corrosion control and mend the cracks in the sheet metal material used for the tankers."

At the Structural Maintenance and Metals Technology sections the state of the art machines such as the OMAX water jet and FARO Arm are a few of the equipment used. They help the Fabrication Flight members to design, weld or create material that has been discontinued.

"The FARO is a three dimensional machine that we use to create or design materials needed that no longer exists," said Staff Sgt. Henry Dungan, 6 MXS metals technology craftsman. "We use the machine to map out the object which appears virtually on the FARO after which we use the OMAX water jet to create."

Not only is creating, mending and welding the material to be used on the aircraft a part of their specialty but also inspecting particular parts brought to them from the maintenance crews.

"We have to inspect the parts of the aircraft for signs of fatigue or stress cracks," said Staff Sgt. Cory Cuadrado, 6 MXS non-destructive site section chief. "At this time we are looking for cracks on the surface of these parts using a dye containing fluid which penetrates surface discontinuities."

Since at times there may be more damage than can be seen with human eyes, the material, once taken to the non-destructive inspection site is analyzed, processed and then evaluated.

Sergeant Cuadrado added that after the material is stripped of all paint, oil and grease the pre-cleaned parts are brought to him in a fluorescent penetrant liquid. Once submerged, the part is placed on a rack and allowed to drain for a specific dwell time. After the dwell time is completed, the part goes through an extensive water wash and cleaning agent process to remove more than 80 percent of the excess surface penetrant and then the part goes into a dryer until the part is dry. The final step of the process is to spray the part with a developer and inspect the part under a blacklight for signs of cracks.

"If any cracks are found we send them to the section where they can be repaired or if un-repairable we notify the owning section so they could order a replacement part," he said.

The Non-Destructive Inspection section members assist with assessing the state of the aircraft materials before they fly. They are the third piece to the flight's mission.

During the Haitian Relief efforts the Fabrication Flight members worked hand in hand with the other maintainers to keep the MacDill tankers flying and mission ready to successfully carry out the tasks given.

According to Sergeant Loop the term "You break it, we mend it" coins the Fabrication Flight's mission.

"If you suspect it, we check it; if you break it, we make it. The Fantastic 'Fab' Flight keeps the aircraft flying high and safe."