Matthew RothgebProgram Manager & Group Leader

Matthew.Rothgeb@udri.udayton.edu

Capabilities and Facilities ReviewCoatings Corrosion and Erosion Group (CCEG), in support of the Coatings, Corrosion and Erosion Laboratory (CCEL) at WPAFB

UDRI Capabilities

• Advanced Manufacturing• Autonomy• Energy and Power• Human Technologies• Hypersonics• Materials• Sensors• Software• Structures and Systems• Sustainment

• Advanced Composites

• Adv. High Temp Materials

• Adv. Materials Characterization

• Aerospace Materials Sustainment

• Coatings and Corrosion• Composites Mfg. and Testing

• Fluids and Lubricants

• Materials Characterization• Multifunctional Structures and

Materials

• Nanoelectronic Materials, M&P

• Nondestructive Evaluation

• Particle Erosion • Rain Erosion• Sealant and Elastomeric Materials

• Structures and Materials Evaluation

UDRI Supports AFRL/RX Materials and Manufacturing Directorate

• AFRL/RXS - Systems Support Division

The Systems Support Division provides quick-reaction materials and processes support to a wide range of Air Force customer organizations, including Air Logistics Centers, Operational Commands, product centers and test ranges. It conducts development programs to satisfy customer needs and ensure effective and timely use of materials and processes in Air Force applications, including sustainment of the current aircraft fleet. The division performs structural and electronic/electrical root cause/failure analyses, recommends solutions and provides lessons learned to developers and end users. The division also supports materials manufacturing and processing needs resulting from production assessments and field services. Systems Support manages the Air Force Electrostatic Discharge Program, Air Force oversight of the DoD Energy and Environmental Program, the Air Force Coatings Technology Integration Program, and the Air Force Rain/Particle Erosion Facility.

• AFRL/RXSS - Logistics System Support BranchThe Logistics Systems Support Branch delivers rapid expertise, solutions, and technologies to meet Air Force customer needs in materials and processing, manufacturing/fabrication, corrosion control, coatings integration, sealant and elastomers, and specialty aircraft materials affordability and sustainment. It also provides materials and processes consultation to resolve the issues through the application of best practices or the use of advanced technologies.

Scope/FocusProvide prompt and dependable organic and inorganic corrosion protection schemes and coating technologies and solutions to our Air Force Logistics Centers (ALC), System Program Offices (SPO), commercial, and academic customers and suppliers by performing comprehensive testing, characterization, and evaluation of coating systems products, equipment, and processes to determine compliance, compatibility, and performance properties prior to recommending transition to field use.

AFRLRXSS

Field Vendor

Coatings, Corrosion and Erosion Laboratory (CCEL)

• 6 Q-Fog Cabinets – Performs a wide range of accelerated

corrosion tests including: Salt Spray, Prohesion, GMW14872, Humidity

– Experimental Cabinet(s) - (Ozone + Humidity/Salt Spray + UV)

• Each Chamber holds 60 panels• ESPEC Environmental Chambers• Ovens, Freezer, Steam Autoclave• Keyence Microscope to 5000x, ATR-FTIR,

MacBeth 7000A ColorEye

Coatings Group Capabilities at RX

Coating Application Capability:• Climate-Controlled Paint Booth: paint application

over a range of environmental conditions: – 40 - 100 ±5°F; 20 - 90 ±5% RH

• Sample sizes: from very small to large sections (4 feet by 8 feet)

• Climate-Controlled Wet Process Preparation• Process Line for coating application per MIL-spec and

AF T.O. requirements– Cr and Cr-free materials

• Data from Drying Time Recorders used to “dial in” temperature and humidity testing in paint booth

• Two ambient booths also available – small to large• One very large booth (ambient) available soon

Coatings Group Capabilities at RX

• 15 QSUN Xenon Arc Cabinets– Max sample size of 17x 17-inches• 5 QUV Test Chambers

– Max sample size of 12x12 inches• 2,430 h (101 days) in a Q-Sun

gives the same UV dosage as a year in Arizona, and 2,044 h (85 days) gives the same UV dosage as a year in Florida (Q-Panel Data)

Coatings Group Capabilities at RX

• Developed powder coating process for Hill AFB– Developed powder coating equipment, identified and tested powder materials

• Cr(VI)-free and Low-VOC Flexible Aircraft Primer for KC-46– Cr(VI) & high-VOC version only one available and a flexible primer is required per FAA

• Robotic Plural Component Coating System Development and Application

– Partner project with efforts between AFLCMC and AFRL RXSS

• Coating and Corrosion Evaluation System Development

– Project with AFRL RXSS and Subcontract with Luna– WISE-MP, CCDM

• Other topics (R&D)– Isocyanate-free topcoats, multifunctional coatings, Mg-rich primer, flexible primers,

primerless topcoats, drag reduction coatings, oliophobic/hydrophobic coatings, laser depainting, plasma depainting, etc.

Past and Present R&D Projects

Weather Instrumentation and Specialized Environmental -Monitoring Platform (WISE-MP)

• WISE-MP – Supports CCDM/ACES– NO, NO2, NOx – 0-20ppm, 0.4ppb detection limit, 1ppb precision, <60sec response time – O3 – 0-20ppm, 0.5 detection limit, 1ppb precision, <30sec response time

– SO2 – 0-10 ppm, 0.5ppb detection limit, 1ppb precision, <90sec response time – Optional: CO, H2S, Particulate Matter (PM10, PM4, PM2.5, PM1), VOC– Temperature (-60ºF to +140ºF) ± 0.17ºF @68ºF – Relative Humidity (0 to 100% RH) ± 3% from 0-90% RH // ±5%RH from 90-100% – Air Pressure (600 to 1100 hPa) ± 0.5 hPa from +32ºF - +86ºF // ± 1 hPa at -60ºF - +140ºF– Rainfall (Resolution – 0.01mm) – Better than 5% accuracy for long-term accumulation. – Rain Intensity (Running one minute average in 10 second steps)– Wind Speed (0 – 60 m/s) – average, max, min – accuracy ± 3% at 10m/s

– Wind Direction (Azimuth – 0-360º) – average, max, min – accuracy ± 3º at 10 m/s– Chloride Monitoring – Continuous Monitoring with 1 week resolution

ACES Chamber

• Accelerated Combined-Effects Simulation Chamber– Phase I – Dynamic Multivariate Accellerated Combined Environment Chambero Ozone, Salt, UV-Ao Effects and Morphology of Corrosion vs. Environmental Exposure (at KSC)

– Phase II – ACES – Delivered to AFRL in August 2018o Ozone, Salt, UV, NOx, SO2, Etc.o Simulate the real world (via Data from WISE-MP)o Confirm resultso Accelerate testing

The Impact Erosion Test Facility is a resource available to the needs of the USAF and the NationEquipment and personnel have directly supported all three military branches and many other USG organizations:DoE - NASA – FAA – DTRA – GSIA – DIA - DLA

Facilities are available for unclassified and classified work

Support of small and big businesses from SBIRs to OEMs

Erosion Capabilities

Leading EdgeRain Erosion Damage

RXSS asset operational since 1968 capable of simulating subsonic flight (max 650 mph) for a calibrated 1”/hr rainfall with droplet range of 1.8 – 2.2 mm in size• The gold standard for qualification of aerospace

materials susceptible to rain erosion damage (ASTM G73)

• At least 5 commercial/military material specifications require rain erosion qualification testing per the test facility capabilities

• More than 80,000 specimen evaluations conducted for over 40 years

NoseRadome

Whirling Arm Rain Erosion Rig

Supersonic Rain Erosion Rig (SuRE)

Equipment simulates impact effects of high speed flight through rain for transonic & supersonic speeds up to Mach 2+ and for rain drop sizes between 0.5 - 3 mm

Droplet Imagesat 1200 ft/sec

• Unique capability for large & full scale components

• High speed videography

• Fills gap between sub/transonic rain erosion & high speed test track capabilities

• R&D capability feeds into predictive multi-scale physical models for systems in rain in trans-supersonic flight regimes

Ambient Particle Erosion Rig

Particle erosion apparatus to simulate dust effects on aircraft surfaces in a dust laden environment at ambient temperatures • Primarily used to evaluate particle erosion of

transparency & infrared window materials per

ASTM F1864

• Upgraded in 2004 to accommodate tri-service

customer requests for sand erosion testing of rotor

blades leading edge materials/coatings

• 2007 “Sand Erosion Test Method” project

resulted in protocol defined in new MIL-STD-3033

• Apparatus to simulate dust effects in high temperature aircraft environments

• 15 cfm of air/gas mixture is heated to over 1300 °C for stable continuous and cyclic exposure testing in a lab environment (currently reached 1200 °C in limited testing)

• Precision particle feed system can meter a variety of test and natural dusts into the heated oxidizing air flow

• Test section is a castable refractory ceramic allowing a multitude of specimen geometries and flow paths

Hot Erosion Rig

Physical testing is only one aspect of the work performed:

• Natural materials analysis

• Theater geological/geophysical issues

• Media development for accelerated testing environments

• Mishap investigations

• Member DoD-OSD Rotor Blade Erosion Working Group

• Member DoD-OSD Joint Turbine Engine Sand Ingestion Working Group (JTESWG)

Erosion Capabilities

Tools dedicated to sand and dust analysis• Optical petrography & microscopy

• Scanning electron microscopy (SEM)

• Energy dispersive X-ray analysis (EDS)

• X-ray diffraction and X-ray fluorescence (XRD-XRF)

• Differential scanning calorimetry (DSC)

• Sample preparation station

• High temperature reducing environment furnace

Sand and Dust Characterization

AFRL/RXSS is home to Erosion Test Media:

AFRL01 – Accelerated desert sand abrasion & wear (Mil Spec 3033)

AFRL02* – Desert dust for thermochemical compatibility testing

AFRL03* – Desert dust for GTE ingestion testing

AFRL04 – Residue free, high temperature flow visualization media for GTE

ingestion testing

* Available commercially from Powder Technology Inc., Burnsville MN

Test Media Development

Other Capabilities within CCEG

•CSE•SECPTRE

Corrosion Science and Engineering Team

• Fundamental Corrosion Science•Modeling (chemical structural analysis and life prediction)• Corrosion Testing (electrochemical, accelerated lab, field

exposure, stress fatigue and salt fog)• Corrosion Analysis• Surface Analysis• Corrosion Prevention Technology• Corrosion Inspection and Characterization• Coatings Evaluation and Development• Coatings Research

Space Combined Effects Primary Test and Research Equipment (SECPTRE)

• Primary use is to simulate the conditions of MEO to GEO with variable temperature, accelerated UV, near visible UV and electron exposures while in vacuum.

• During exposure, SCEPTRE measures specimen spectral reflectance, solar absorptance, temperature, electron flux, gross outgassing, and the spectral irradiance of the UV source.

• Simulates a variety of orbital environments and accurately reproduces the rate and extent to which a material will degrade in the actual space environment.

Contact Information

Matt Rothgeb CCEG Program Managermatthew.rothgeb.ctr@us.af.milmathew.rothgeb@udri.udayton.edu937-255-4017 (O)321-749-9668 (C)