0850Adv Aircraft Corr Prot-Osborne-Boeing

March 8-11, 2004 2004 Air Force Corrosion Program Conference Slide 1

Advanced Aircraft Corrosion ProtectionA Coatings System Approach

to Reduce Chromates

Joseph H. OsborneBoeing Phantom Works – Seattle

[email protected] 425-237-8518

mailto:[email protected]


Getting the Chromate “Out”

• Reduced Chromate– Choice depends on local regulations

• Key Performance Goal: Long Term Corrosion Protection– Coating system: 2000+ hours neutral salt fog

• Conversion coating: 168 hours

Chromate Conversion Coating

Chromate Primer

Topcoat

substrate

Chromate Conversion Coating

NonChromate Primer

Topcoat

substrate

NonChromate Conversion Coating

Chromate Primer

Topcoat

substrate

NonChromate Conversion Coating

NonChromate Primer

Topcoat

substrate

• Adhesion Promoters• Don’t meet MIL-C-81706


Requirements for Successful Technology Transition

Meet Performance Requirements– Capable Engineering properties

• Meet performance specifications– Adaptable Processing characteristics

• Appropriate for production environment

Specification coverage– Technical Order / Military or industry specifications

• What are the “real” performance requirements?– Current specification limits– Equal or better than today’s coating systems

• Safety of personnel and airframe/vehicle is prime concern


Overview

• AACP program– Goals– AC-131/Boegel– Performance data– Producibility data

• Other applications– Painting– Bonding


Program Description

• Funded by Aging Systems Command/AFRL– Aging Aircraft Office (ASC/AAAV)

• Transition Demonstration of coating system– Topcoat technologies developed for C-17 (APC)– Nonchromate Conversion Coating technologies developed by

AFOSR/AFRL/DARPA (Boegel/AC-131)• Program Plan

– Phase I: Laboratory validation of performance and process – Phase II: Flight test

• Coat test vehicles, summer 2004

• Deliverables:– Coating system description– Laboratory validation data– Analysis of flight testing– Processing description for T.O. 1-1-8


AACP Coating System

Flight Operations

DepaintDepot

MaintenanceRepaint

Repaint

Clean & Seal

Alkaline Clean

Brighten

Conversion Coat

(AC-131)

Prime & Paint

(Cr primer,APC Topcoat)

• Cleaning steps determined by conversion coating– CCC requires active “bright” metal surface– AC-131/Boegel adheres to surface oxides

• Doesn’t require brightener process• Does require clean waterbreak free surface


Performance and Producability Verification

• Boegel EPII• Cleaning and Brightening• Depainting• Corrosion and weathering data


AC-131/Boegel conversion coating

• Boegel is Boeing Developmental name – Licensed to AC Tech

• AC-131 (painting), AC-130 (bonding)

• Mixed Zr/Si oxide system• Silane coupling agent chosen to match primer, sealant, or

adhesive chemistry– AC-131/Boegel-EPII is epoxy functionalized – epoxy primers/adhesives– Boegel-AM is amino functionalized – polyimide adhesives

• Water solution -- ~3-5% solids• Spray on, no rinse, ambient dry• Little or no waste

– Neutralize and sewer• Superior adhesion

– Aluminum, titanium, CRES• Common surface preparation

• “pigmentable” for corrosion protection and optical properties


AC-131/Boegel EPII

• Optimized for adhesion of epoxy coatings – Superior adhesion to Al, Ti, CRES

• A water-like solution with reactive ingredients– Long shelf life, 12 hour pot life once mixed– 2 part kit, prepare amount needed for job

• Spray applied to part/airplane– “spray drench”

• Solution flows off part– “dripless spray”

• Apply to wet surface but minimize drainage

• Dry in place, no rinse required– Thick coatings reduce paint adhesion

• Remove drips and solution from pockets and recesses


Large volume applications

• BCA Paint Hanger Trials– Replacement for Alodine 1000– Meets production engineering

reqmt’s on new clad aluminum fuselage

• Production Laboratory Testing– Ability to mix and use– Process compatibility with masking and

equipment – Ability to Strip– Paper/Tape compatibility– Compatibility over Composites– Wet/Dry Adhesion– Corrosion

• Sandwich • Filiform• Salt Spray

– Rain Erosion– Forward and Reverse Impact– Acrylic Crazing– Titanium Stress Corrosion– Hydrogen Embrittlement


Inspectability of Boegel/AC-131

• Dyes and fluorescents• Good color definition with dyes• No effect on adhesion performance• Weatherability/cleanability data to be developed

Alodine1200S

AC-131 withWater Soluble dyesAC-131


Process Schemes with AACP System

• Alkaline clean / brighten / AC-131 / Prime&Paint– Eliminates chromate conversion coating– Reduces rinse water (no rinse after AC-131/Boegel)– Meets current engineering requirements

Clean & Seal

Alkaline Clean

Brighten

Conversion Coat

Prime & Paint

Clean & Seal

Alkaline/acid Clean

Conversion Coat

Prime & Paint

• “detergent” clean / AC-131 / Prime&Paint– Eliminates chromate conversion coating– Eliminates brightener step and associated rinses– Shows promise – need to define cleaning process

“Low

Ris

k”

“Str

etch

Goa

l”


Depainting

0

5

10

15

20

25

PR 3133(Ammonia)

PR 5044(Peroxide)

PR5000 / PR3170(Peroxide /

Solvent)

TRP Inc. ES-1(MeCl2 / Formic

Acid)

Ho

urs

(80

-100

% P

rim

er R

emo

val)

Alodine / MIL-PRF-23377 Alodine / MIL-PRF-85582

Boegel EP II / MIL-PRF-23377 Boegel EP II / MIL-PRF-85582

AA2024

0

5

10

15

20

25

PR 3133(Ammonia)

PR 5044(Peroxide)

PR5000 / PR3170(Peroxide /

Solvent)

TRP Inc. ES-1(MeCl2 / Formic

Acid)

Ho

urs

(80

-100

% P

rim

er R

emo

val)

Boegel EP II / MIL-PRF-23377 Boegel EP II / MIL-PRF-85582

Ti –6,4

• Does not “depaint” like conventional systems– Topcoat removes first from primer– Additional dwell time or manual effort needed to remove primer


ACRAC Coatings at 5688 Hours NSS

• AA2024-T3 substrates

Chemidize/Boegel/85582/APC-g

CB82G

Boeclene/Alodine/85582/APC-g

BA82G

Boeclene/Boegel/85582/APC-g

BB82G

Boeclene/Alodine10PW22-2/APC-g

BA10G


ACRAC ASTM B117 Salt Spray – 2500 hrs

MIL-PRF-85582Deft 99-GY-001

Alodine 1200S AC 131


ACRAC ASTM G85-A5 “Prohesion” – 2500 hr

MIL-PRF-85582Deft 99-GY-001

Alodine 1200S AC 131


Weathering Data at 1500 Hours

0

1

2

3

4

5

6

7

8

9

Akzo10P20-4/ECW-104

Deft02Y040

Deft44GN72

SWE90G203

Akzo10P20-4/ECW-104

Deft02Y040

Deft44GN72

PRC1432GV

PRC1432GV &

Deft02Y040

SWE90G203

60°85°DeltaE

Deft 03-GY-321 Deft 99-GY-001


Specification Summary

Spec # Process Implementations

BAC5663 Aluminum Alloy Conversion Coating for Paint

BCA-Fuselage rivets(737 console)(final paint)

D950-10313-1, Rev C; BSMS-25-002; BSPS-07-002

Titanium Alloy Conversion Coating for Paint

F-22

BSMS-25-001; BSPS-07-001, HP 4-136 Rev A; D950-10413-1 Rev A, D720PM-PP006, Rev A; S697-10090-1 Rev A; 5PTPHB25; Assorted DoD TOs

Titanium Alloy Adhesive Bonding

F-22; X-32; B-2 spares; Delta IV; AH-64; F-22; CH-47; CH-46

D210-13577-1; SRM 51-70-09; SRM 51-70-10; Assorted DoD TOs

Aluminum Alloy Adhesive Bonding

CH-47, Airline SRMs, C-5

HP 4-136 MRB Stainless Steel Adhesive Bonding

AH-64


Adhesion to Boegel-EPII Coated Rivets

Depainting

Rain ErosionAC-131 coated

Scribed – wet tape

“Rivet Rash”

•Clad Fuselage skins•“leached” rivets

OTS

AC-131


F-22 Forward Boom

• Phosphate-fluoride is typical conversion coating for titanium

• Process tanks not available, so different approach was needed.

• First application– AV #2– 1997

• Current:– Forward & aft booms– Titanium tubes

HF/HNO3 etch Phosphate fluoride Boegel

goodpoorpoor


Titanium bonding

• B-2 Ti core to composite• Replaces chromic acid anodize

• X-32 Ti-Ti, Ti-composite• F-22

–Aft Boom composite reinforcement–Studs for insulation blanket installation–Repair/reinforcement of structure

• Delta IV Ti-composite end fittings

• Helicopters–Comanche (RAH-66) rotor caps,

components


737 Aisle Stand Frame Cell

• Produced at Boeing-Portland– AA7075 parts are currently anodized and painted in

separate facilities– BMS10-11 primer, Nextel Suede finish coat– Cell designed to produce frames in a dedicated line

• BAC5663 Released– Mechanical (grit blast) and chemical deox– Boegel EPII processing is the enabling technology

• Replaces anodizing– Estimated benefit

• Run time reduced by ½• Flow time reduced from 27 to 2 days

• Implementation Strategy– Probably drawing change


Process Name: AISLE STAND FRAMECELL

Model Number: 737Model Name:

Scope ofOperations

Standard Work Sheet

From: Raw Material to finished painted part and in

To: Stores in two days

Date:

Dept. Head Supervisor

QualityCheck

SafetyPrecaution

Standard Workin-process

#. of pieces of std.work in-process

TAKTTime

OperatorNumber

incoming

fromT-20

Goals

TabRemovalStraighten

DrillTap

Penetrant

Bo

e-g

el

ap

plic

atio

n

PartMark

737 Monthly Rate 14 PlanesDaily Requirement 3.5 Parts

Takt Time = 137 Min.70 Parts Per Month

Customer Requirements

MaskHandFinish

Clean

Sandblast

2nd shift operationavailable for additional

part numbers

outgoing

PaintBooth

254A1307-1254A1237-2254A1237-4254A1238-3254A1239-3

= ship set

C/T 5 minC/T 1 minC/T 10 minC/T 1 min

C/T 45 minREF. QA op

C/T 2 min C/T 2 min C/T 2 minC/T 2 min C/T 2 min

C/T 2 min

Bo

e-g

el D

wel

llo

cati

on

Boe-gel resttime = 60 min

27 flow days reducedto 2 days @ a one

shift operation

134 minutes for firstpart through the line

Total touch time =74 minutes

Planning standards =29 minutes

9/20/02

Aisle Stand Flow Diagram


OC-ALC Backshop Demonstration

• Coated several parts in TF-33 refurb shop • February 18, 2004

– Glen Graham is technical point of contact– Evaluate potential for work cell environment

• TF-33 cowl– Scuff sand/overcoat application

• Needed cleaning to waterbreak free condition• Scrap part, not painted

• Engine support assembly (??)– Titanium panels, stainless rails, aluminum brackets– Cleaned to WBF, coated, 2 hour dry, prime

• Miscellaneous aluminum brackets– Racked for painting, coated, 2 hour dry, prime

• not cleaned well, showed orange peel (marginally acceptable)


Conclusions

• AC-131/Boegel EPII coating systems are capable for depot and field processing environments– Performance equivalent to present systems

• Chromated primer is still required– Superior adhesion to aluminum, titanium, and stainless steel– Colored for process and in-process and end-item inspection– Potential to eliminate aggressive brightening

• Reduction in process steps and processing time– Potential to provide stand-alone corrosion protection

• Ongoing inhibitor incorporation work.

• Flight testing in AACP program will validate performance capabilities for mold line use– Language for T.O. 1-1-8 for implementation

• Other potential painting and bonding applications– Adaptable to multiple part configurations and work cells

0850Adv Aircraft Corr Prot-Osborne-Boeing

Documents

Transcript of 0850Adv Aircraft Corr Prot-Osborne-Boeing