Air Force Materiel Commandproceedings.ndia.org/jsem2007/3855_Geib.pdf · 11 JTP Progress •...
Transcript of Air Force Materiel Commandproceedings.ndia.org/jsem2007/3855_Geib.pdf · 11 JTP Progress •...
Low Temperature Cure Powder
CoatingESTCP PROJECT WP-0614
Mr. Christopher W. GeibScience Applications International Corporation 23 May 2007
Integrity ~ Service ~ Excellence
One Materiel CommandAir Force Materiel Command
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Overview
• Background• Project Concept
– Past– Present and Future
• Near-Term– Joint Test Protocol– Field Service Evaluations
• LTCPC Participants• JTP Progress
– JTP Test Results• FSE Progress• Expected Project Outcome• Schedule
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Background
• Temperature-sensitive Al & Mg is used throughout DoD for high durability & low weight
• Al and Mg can’t withstand the high-T cure ~350F of current powder coatings
• Results in continued reliance on high VOC solvent-based coatings
• SERDP Project PP-1268 developed VOC & HAP free, low temp cure coating for low-T alloys
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Background (cont.)
Traditional Primers & Topcoats
Waterborne Primers & Topcoats
Traditional Powder Coatings
Low-Temperature Cure Powder Coating
Compatible Substrates
Steel, Aluminum, Magnesium, Composites
Steel, Aluminum, Magnesium, Composites
Steel Steel, Aluminum, Magnesium
Advantages
Solvent flash-off leaves a uniform coating free of blemishes
VOC and HAP content are significantly reduced relative to traditional primers and topcoats
Single application coating; No VOC or HAP production; fast cure
Single application coating; No VOC’s or HAP’s; fast low temp cure ~30min@250F; enhanced corrosion inhibitors; improved transfer efficiency; primer application eliminated
Disadvantages
Environmental burden of high VOC and HAP production and release
Longer cure times than traditional primers and topcoats; still has VOC and HAP
High temp cure ~350F; Al and Mg substrates compromised; Can’t be applied at field level due to high curing temperature requirement
Currently, only proposed for depot production environments
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Background (cont.)Current Process
Proposed Process
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Project Concept
Past:• Original SERDP-funded
project explored low temperature cure chemistries
• Crosslink Powder Coatings Inc. iteratively reformulated LTCPC for testing
• Performance testing based on requirements of applicable MIL-PRFs
• Resulted in exterior-use, corrosion-protection powder coating that cures at 120°C within 30 minutes
Present & Future:• Partnership with Navy as part
of ESTCP-funded effort• Development of JTP
providing stakeholders additional performance data
• FSE to validate LTCPC within the operational environments
• Quantification of expected environmental savings
• Technology transition to Air Force and Navy depot production environment
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Near Term
For remainder of FY07:• Complete Joint Test Plan requirements• Generation of Joint Test Report• Initiation of USAF & USN FSEs
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Near Term – Joint Test Protocol
JTP:• Six substrates
(4 Al, 1 Mg, 1 Steel)• Eight performance
tests• HAFB Powder Coat
Facility (Oct 2006)• Initiated coupon
testing (Dec 2006)
Additional testing:• NASA special
interest items
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Near Term – Field Service Evaluation
• Ten performance tests for field-coated coupons
• Various Air Force & Navy components
• Qualitative field inspection methods
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LTCPC Participants
Validation Phase:• S&EL, Hill AFB, UT• NAVAIR Pax River, MD• CTC, Johnstown, PA• NASA, Kennedy Space
Center, FL
Evaluation Phase:• OO-ALC, Hill AFB, UT• OC-ALC, Tinker AFB,
OK• WR-ALC, Robins AFB,
GA• FRC NW, Whidbey
Island, WA• FRC SW, North Island,
CA
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JTP Progress• Results for
– Coating appearance– SO2 corrosion resistance– Filiform corrosion resistance– Cross cut adhesion– Impact flexibility– Strippability
• LTCPC passed all testing for each substrate considered
• No deficiencies or anomalies noted
• Salt fog and cyclic corrosion resistance testing ECD: June 07
JTP Substrate Matrix
2024-T0 Aluminum0.020” thick2024-T3 Aluminum0.032” thick6061-T6 Aluminum0.032” thick2024-T3 Clad Aluminum0.032” thickAZ31B Magnesium0.063” thick4130 Steel0.032” thick
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JTP Test Results
LTCPC AppearanceSubstrate Outcome
6061-T6 PassedMg Passed
Steel Passed
Control: PENDINGLTCPC: PENDING
Steel
Control: PassedLTCPC: Passed
6061-T6
Control: Passed
Control: Passed
LTCPC: PassedMg
* After 2000 hours
LTCPC: Passed2024-T3
OutcomeSubstrate
Salt Fog Corrosion Resistance*
EXAMPLE
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JTP Test Results (cont.)SO2 Corrosion ResistanceSubstrate Outcome
LTCPC: MARGINAL2024-T3
Control: PASSEDLTCPC: FAIL
6061-T6Control: FAILLTCPC: PENDING
SteelControl: PENDING
ControlLTCPC:
Steel
Control:
* After 500 hours
LTCPC:2024-T3 Clad
OutcomeSubstrateCyclic Corrosion Resistance*
RESULTS
PENDING
EXAMPLE
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JTP Test Results (cont.)
Filiform Corrosion ResistanceSubstrate Outcome
LTCPC: PASSED2024-T3 Clad Control: FAILED
LTCPC: PASSEDControl: PASSED
Control: PASSEDLTCPC: PASSED
Mg
Control: PASSEDSteel
LTCPC: PASSED6061-T6
OutcomeSubstrateCross Cut Adhesion
EXAMPLE
EXAMPLE
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JTP Test Results (cont.)
StrippabilitySubstrate Outcome
LTCPC:2024-T3
Control:LTCPC:
6061-T6Control:LTCPC:2024-T3
Clad Control:
Control:LTCPC:
LTCPC:Mg
SteelControl:
Control: PassedLTCPC: Passed
2024-T0
OutcomeSubstrateImpact Flexibility
EXAMPLE
RESULTS
PENDING
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FSE Progress• Identified AF and Navy components
– F-15 & F-16 Gear boxes– C-130 Landing gear doors– TF-33 Engine stators– Munitions skids– Aircraft tow bars– MJ-1 bomb lift trucks
• Slated for July 2007 start• Inspection intervals
– Non SOF: 100 flight hours– GSE: 6 months
• Exposure to demanding carrier environment for Navy components– Naturally corrosive– Stringent coating requirements
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Expected Project Outcome
• Full performance validation of LTCPC• Quantifiable environmental savings• Modification of applicable specs and
TOs• Transition to DoD depot-level facilities
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Schedule
• Demonstration Plan – July 2007• Joint Test Report – July 2007• Completion of FSE – Feb 2009• Cost & Performance Report – Dec 2009• Final Report – Dec 2009
Project Schedule
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Summary
• Validation Phase completion imminent• Evaluation Phase underway• Significant environmental impact• Focused attention on transition to field
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References
• Bloker, TSgt B. (2004) Air Force Link - Photos. Retrieved August 14, 2006, from http://www.af.mil/shared/media/photodb/photos/041110-F-2295B-083.jpg
• Kurle, Maj D. (2006) Air Force Link – Photos. Retrieved January 12, 2007, from http://www.af.mil/shared/media/photodb/photos/061104-F-3849K-201.jpg
• Nelsen II, J. T. (2003). US Maps Clip Art. Retrieved January 11, 2007, from National War College Military Image Collection Web site: http://www.ndu.edu/nwc/nwcCLIPARt/MAPS-FLAGS/US_Maps/us-maps.html
• Whidbey Island Support Equipment 900 Division Web Site.(n.d.) Retrieved August 16, 2006, from http://aimdwi.ahf.nmci.navy.mil/IMAGES/P1009064.JPG
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Questions?