Flight Line Replaceable Modules (LRMs) are the foundation for modern day architectures in fighters such as the F-22. The 2-level maintenance concept (flight line to depot) reduces costs for spares and base level repair of circuit cards. However, this maintenance concept is predicated on the ability of the software to isolate failures down to the LRM or circuit card level. The types of failures that result from worn and corroded connectors result in large ambiguity groups; thus, making isolation to the circuit card level difficult. The vibration, thermal, humidity and corrosion environments of the F-22 are severe. Similarly, the ESD environment (for F-22 flight line maintenance) is severe because maintenance is performed without grounding straps or any special handling requirements. Hardware designed for use in this environment must be easily installed, capable of performing in a severe environment while maintaining high data rates without interruption. This paper identifies the F-22 risk reduction approach taken to mitigate the effects of the severe environments. The design & analytical approach taken during the program development phase offers important insight into the methods needed for predicting and analyzing hardware installation within the severe vibration and thermal environments commonly found in today’s fighter aircraft.

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