What’s New with Coatings in 2018? - NSRP · 2018-10-12 · Updated MIL-STD-1687 to Technical...
Transcript of What’s New with Coatings in 2018? - NSRP · 2018-10-12 · Updated MIL-STD-1687 to Technical...
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NAVAL SEA SYSTEMS COMMAND
What’s New with Coatings in 2018?
NSRP
Charleston, SC
March 2018
Howard Castle
SEA 05P2
(202) 781-5082
[email protected] Distribution A: Approved for Public Release
OBJECTIVES
Summarize evolving Naval Sea Systems Command (NAVSEA)
organization and coating requirements.
Review some key changes regarding recent Standard Items and
MIL specs.
Present recent and planned updates to specifications affecting in-
service and new construction ships.
Distribution A: Approved for Public Release 2
Code Product Related Specs All All Technical Products, Managerial All
AF Antifouling Coating Systems MIL-PRF-24647
TNK Tank Coatings, Epoxy Primers MIL-PRF-23236
MIL-DTL-24441
PRM Primers, Single Component TT-P-645
TOP Topside, Alkyds & Polysiloxanes MIL-PRF-24635
INT Interior Coatings (SEA 08) MIL-DTL-24607
MIL-PRF-24596
MIL-DTL-15090
MIL-DTL-1115
HT High Temp Coatings, Metallic TT-P-28
PWD Powder, Interior, Cosmetic MIL-PRF-24712
NSK Nonskid MIL-PRF-24667
DCK Deck Coverings MIL-D-3134
MIL-PRF-3135
MIL-PRF-24613
MIL-PRF-32171
SUR Abrasive blasting, surface prep MIL-A-22262
SEL Sealants & Preservatives MIL-PRF-16173
NAVSEAINST 9630.1
DOC Policy Documents NSTM 631, NSTM 634
S636-MAN, CCAMM
Standard Item 009-32
Standard Item 009-26
COR Corrosion/PCOE Policy/Design DODI 5000.67
RSH Research & Development To be determined
UNDS Regulations, Underwater hull TBD
NAVAIR
Aircraft Engines
SEA 08R
SEA 08T
TWH: Underwater
Hull Husbandry
SDMs: Surface,
Submarine,
Carrier
Technical Authority Pyramid - Coatings & Corrosion Control Draft: Dec 2017
Navy Employee Navy Developmental Employee Contractor
Ingle all
Castle (EM)
All, COR
Lemieux (EA)
All, RSH
Vacant (EM)
NSK, All
Wegand (EM)
RSH, NSK
Lattner (EM) COR
Haslbeck (EM)
All, AF
J. Martin (EM)
TOP, TNK
Melhuish (EM)
All, NSK
Brinckerhoff (EM) All
Tagert (EM)
TNK, NSK
Vacant (EM)
VA-Class
Jones (EM)
NSK, DCK
Iezzi (EM)
RSH TOP
Smith (EM)
UNDS
Wigle (EM)
CCAT
Slebodnick (EM)
RSH, TNK, NSK
Truman (LE) COR
Carroll (LE) NSK
Kuljian NSK, RSH
Cassidy (LE)
DOCs
Stanke TNK, All
White INT
Adams (LE)
NSK, RSH
Miller TNK, NSK
Zuwiala COR
Park DOCs
Foster All
Hadziliac Cor, Doc
F. Martin HT, COR
Spicer TNK, NSK
Holm (LE) AF
Webb RSH
Intern All
Ellor COR
Ault (LE)
TNK, RSH
Langaster (LE) TNK
Ranero (EM)
All, NSK
EAs
EMs
LEs
Kogler SUR
TWH
Delegated signature authority
Ong (EA) All
Hicks (EM)
NSK, TNK
Duckworth (EA) All
Distribution A: Approved for Public Release
HQ
Messier COR, DOC
NAVAIR 4.4
Aircraft Engines
Ingle all
Castle (EM)
All, COR
Vacant (EM)
NSK, All
CNSP N42
Aviation
USFF N43
Maintenance
USMC AVN
Aviation
Preston- Baker (LE)
All RSH
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NAVSEA Strategic Business Plan NAVSEA Strategic Business Plan 2018-2022, has three key mission priorities:
1. On-Time Delivery of Ships and Submarines
2. Culture of Affordability
3. Cybersecurity
NAVSEA addresses these items through continual, ongoing interactions with shipbuilding
and ship repair community:
Brief at antifouling
program review
Attend FNC review
CWP
Funded NAVSEA
program.
NAVSEA/Shipyard teams
Brief at meetings
Meet with industry
Serve on Executive
Committee
Attend quarterly review
Brief at NSRP Surface
Preparation and Coatings
Panel Meetings
SSRAC
MegaRust
PCOE
Chair, annual public
meeting to update
Standard Item 009-32
Vendors,
government, and
industry submit
changes, all changes
evaluated
Distribution A: Approved for Public Release 4
Standard Item Updates
Development and publication of new Standard Item 009-124 “Thermal Spray Nonskid
Application; accomplish” as of 6 Mar 2018
- Defines process requirements for application of TSN products
- Requires thermal spray wire qualified to MIL-PRF-32577
Minor updates to 009-26 “Deck Covering; accomplish” captured in 1 Oct 2017 update
- References updated to new MIL-PRF-32584 specification
- Peel & stick terminology updated
Regular updates to Standard Item 009-32 “Cleaning and Painting Requirements;
accomplish” pending imminent release. Key changes:
- Added requirement to use low-density “Comp D” aggregate nonskid on amphibious
class ships to reduce risk of FOD
- Eliminate requirement for chloride/conductivity checks of potable, reserve feedwater,
and freshwater drain collecting tanks
- Added “flight deck nonskid” to areas not allowed to waive requirements when
performing touch-up of newly installed systems
- New attachments D & E for ICCP sprayable dielectric shield application
Distribution A: Approved for Public Release 5
Does NAVSEA just keep adding requirements?
Based solely on length of 009-32, the answer could appear to be yes, but…
Of the changes incorporated into FY-19, Ch-2:
38% addressed clarification issues
28% reduced requirements or permitted lower-cost alternatives
34% reflected a new requirement or increased costs
Examples of relaxed requirements include:
- Eliminate SP 1 requirement for tie-downs when hand or power-tool cleaned
prior to waterjetting.
- Permit in-situ high-solids paint repair of louvers when more than 90% of
powder coating is intact and adherent.
- Permit use of low temperature coatings applied to “skin” tanks when
substrate temperatures cannot be maintained over 50°F
Distribution A: Approved for Public Release 6
TSN Technical Requirement Status
TSN Fielding
Vital to Amphibious Ships
& Fleet Operations
FY-18, Change 1
Standard Item
009-32
7 Mar 2017
Military
specification
MIL-PRF-24667C
for epoxy nonskid
2 Sep 2009
Naval Ships
Technical Manual
Chapter 634
1 Jan 2009
Material Installation Process /Qualifications In-service
Distribution A: Approved for Public Release
MRC (Multiple)
for Nonskid
Inspection
and Repair
by Ship’s Force
FY-19 New
NAVSEA
Standard Item
009-124
New military
specification
MIL-PRF-32577
for TSN wire
material.
Update Naval Ships
Technical Manual
Chapter 634 to
Include TSN
Update current
MIL-STD-1687A
to Technical
Publication 1687
Update MRC
for TSN Inspection
and Repair
by Ship’s Force
CURRENT
EPOXY
NONSKID:
NEW
TSN:
STATUS: Published on Published on Published on PDS for Developmental based
12 Jun 2017 6 March 2018 12 Jun 2017 FY-18 Task on current changes to
MRC to reduce risk of
nonskid undercutting
and forming chips
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TSN To Improve Flight Deck Performance
TSN is only material
that can withstand
direct F-35 exhaust
gas impingement.
TSN has low macro-
profile and smaller
“chips” that can
break off lowering
risk of aircraft engine
FOD.
TSN is aluminum and
small (e.g., 400 grit or
smaller) Al2O3 aggregate
as compared with 24-30
grit Al2O3 in conventional
epoxy nonskid. Conventional Nonskid Chips TSN, wear particles , 400 grit aggregate
TSN can resist V-22
exhaust gas heat.
NRL validating that
V-22 exhaust gas
impingement can
crack conventional
nonskid.
Distribution A: Approved for Public Release 8
1.(V)(G) “CONTAINMENT AND VENTILATION INSTALLATION”
Process requires environmental controls on temperature, humidity, and dust.
Design approved by SUPERVISOR per Standard Item 009-01, 009-03, 009-05, etc.
Re-establishment of containment across deck is contractor verification point (V).
Environmental requirements are 55-90ºF ambient temperature, >50ºF deck temperature,
Relative humidity <70%, deck temperature >5ºF above the dew point as trades person verification point (V).
2.(I)(G) “CONDUCTIVITY MEASUREMENT”
Conductivity required (i.e., there are no separate chloride limits) using Bresle or
equivalent method. One reading from first 200 ft²/subsequent 400 ft² with limit of 30 micro-siemens/cm. Requires low pressure waterjet cleaning of any areas with high conductivity.
3.(I)(G) "CLEANLINESS PRIOR TO ABRASIVE BLASTING"
Clean and degrease surface by SSPC-SP 1 before surface preparation, requires verification
using water break test.
One water break test is required for every 200 ft².
4.(I)(G) “SECONDARY SURFACE PREPARATION”
Requires SSPC-SP 5 white metal blast on both general deck surface
and welds using requirements in SURFACE PROFILE section.
5.(I)(G) “SURFACE PROFILE”
Measures profile on the SSPC-SP 5 white metal level of cleanliness
created using 50/50 mixture of 16- to 24-grit virgin Al2O3 abrasive during surface preparation
within 10 hours of removing old nonskid using very thorough water jet cleaning
to SSPC-WJ 2.
Verifies compressed air cleanliness.
Requires ASTM D4417 Method B for profile peak height and ASME B46.1 for profile
texture. Profile shall be between 4.0 and 10.0 mils and texture by
root mean square (RΔq) >0.45 as measured on first 200 ft²/subsequent 400 ft².
Distribution A: Approved for Public Release
Thermal Spray Nonskid Standard Item 009-124 Process
Includes Eleven Government QA Checkpoints
Failed Test
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6.(I)(G) “DUST TEST”
Requires ISO 8502-3 (Rating 2, Class 2) with “just visible” particles no larger
than 40 mils with three readings per 400 ft2.
7.(I)(G) “THERMAL SPRAY APPLICATION MACHINE SETTINGS”
Requires robot settings are same as those used in Technical Publication 1687 process. Check and validate settings at start of work shift.
8.(I)(G) “MANDREL BEND WITNESS PANELS”
Requires three witness panels attached to tie downs
to be removed from deck after first TSN coat and bent
180º over a 2 ¼ inch mandrel at start of each work day.
Only slight edge cracking allowed.
9.(I)(G) “FILM THICKNESS MEASUREMENTS”
Requires film thicknesses demonstrated in Technical Publication 1687 process
to be measured using modified SSPC-PA 2 method to take five spot
spot per every 200 ft2 and to locate and repair thin areas on a +- 3 inch basis.
10.(I)(G) “TSN CLEANLINESS”
Requires wire brush, dry vacuum, or low pressure, vacuum water cleaning,
at 2,500 to 3,000 psi, to clean dust off deck before color top.
11.(I)(G) “COLOR TOPPING HOLIDAY INSPECTION”
Requires wet film thickness of color top and visual inspection of deck.
Requires dark gray and VLA marking colors to be applied direct to TSN.
SUPERVISOR provides final approval of deck.
Standard Item 009-32 has eight (G) points to ensure nonskid quality while Standard Item 009-124 has eleven (G) points.
Thermal Spray Nonskid Standard Item 009-124 Process
Includes Eleven Government QA Checkpoints
Quantity of small particles
Distribution A: Approved for Public Release 10
Plan: Update MIL-STD-1687A to Technical Publication 1687, “THERMAL SPRAY PROCESSES FOR
NAVAL SHIP MACHINERY APPLICATION,” to include requirements for personnel training
and process qualification to apply TSN wire material with the twin-wire arc spray process
and equipment , as-demonstrated by NRL on LHA/LHD.
Key Update Provisions:
- Defines required applicator training.
- Outlines safety requirements.
- Defines applicator qualification process and audit
For Quality Assurance.
- Explains to applicator the entire process.
Updated MIL-STD-1687 to Technical Publication 1687 and change was signed out on 9 Jun 2017.
Update to MIL-STD-1687A on Process Qualifications
Requirements for TSN Applicator Training, Certification & Qualification
Distribution A: Approved for Public Release 11
Plan: New MIL-PRF-32577 “COATING SYSTEM, NONSKID,
METALLIC THERMAL SPRAY APPLICATION” defines the
wire material used with twin-wire arc spray process &
equipment to apply TSN to LHA/LHD flight decks.
Key Material Specification Provisions:
Wires based on aluminum alloys to withstand operational
requirements.
Multiple coats of TSN acceptable to build final coating system.
Wire material Type/Class to specify allowable levels of
hazardous heavy metals.
Wire material Type/Class to define whether wire is solid or cored.
Qualification Tests:
Conformance tests (e.g., metals levels, lubricants, packaging) to be
conducted on wire feed stock.
Coating conformance tests to exclude silicate color topping (need to prepare
a color top specification).
Qualification testing on coating with application parameters demonstrated on LHD
and LHA.
STATUS: New military specification published 12 June 2017.
New TSN Material Specification MIL-PRF-32577
Defines Thermal Spray Wire Requirements
Distribution A: Approved for Public Release 12
● LHA 6 TSN installed using solid wire that is 97% Al / 3% Ti.
● LHD 1 and LHD 5 TSN installed using cored wire that is 5054 Al jacket / aluminum oxide (400 grit) core.
Cross Section: solid core aluminum wire
with elemental Ti.
Cross Section: hollow core aluminum alloy wire
with discrete aluminum oxide particles.
Transfer Efficiency: 68% Transfer Efficiency: 57%
Application Rate: 84 - 112 ft2/hour Application Rate: 84 - 112 ft2/hour
No reportable chromium on MSDS. Chromium reported as 0.15 – 0.35%
MIL-PRF-32577 addresses requirements for both solid and cored TSN wire.
Distribution A: Approved for Public Release
New TSN Material Specification MIL-PRF-32577 Wire Type
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Recent and upcoming MIL spec updates
MIL-PRF-16173:
- Since 1993, spec paragraph 1.2.1 defined the product classes: Class I was defined as
VOC exceeding 340 g/L and Class II was defined as VOC not exceeding 340 g/L.
- Test requirement paragraph 3.4.2 stated: “…the VOC for Class I compounds may
exceed 340 g/L…” and “…Class II shall not exceed 340 g/L…”.
- Resulted in low VOC products on high VOC QPD. Interim update completed to MIL-
PRF-16173 to prevent high and low VOC products from being qualified to same
product classification.
MIL-PRF-24635:
- Interim update planned for MIL-PRF-24635 to define composition category for 1K vs.
2K polysiloxanes to address issues for in-service procurement.
- Ship’s Force preserved 105k ft² on
LHD 2 freeboard in April 2017 using
1K polysiloxane.
- Fleet requires method to procure
products capable of being applied
by Ship’s Force.
- NRL finalizing long-term spec update
to address universal pigment package and total solar reflectance changes. Distribution A: Approved for Public Release
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Recent and upcoming MIL spec updates
MIL-DTL-24441:
- NAVSEA demonstrating new “Type VI” UHS variant of formula product for use on key
submarine tanks
- Initial issues with surface wrinkle phenomenon appear to have been addressed
MIL-PRF-24667:
- Discussed next revision plan at Sept 2017 NSRP meeting.
- NSWCPD initiated rewrite kickoff Feb 2018 with aggressive 2018 plan due to USFF
funding.
- Interim update pending to define “Comp D” low density aggregate nonskid, based on
aggregate hardness and density, and cured nonskid weight/area.
Ballast tank inspection
after two years
Ballast tank inspection
after two years
Distribution A: Approved for Public Release 15
ISSUE: LHD 6 Hazard Assessment Report (HAR) that defined “best practices” for reducing risk of aircraft engine Foreign Object
Damage (FOD) signed on 27 Mar 2017 by: SEA 00, SEA 05, SEA 21, AIR 00, AIR 4.0, CNSF 00, and USMC Deputy
Commandant for Aviation and included:
RISK MITIGATION 2 – Determine if alternative nonskid materials or processes inherently reduce aircraft engine FOD risk.
Publication of Interim Change to MIL-PRF-24667C to create “Composition D” low density nonskid requirements and update to
Standard Item 009-32 to require use of Composition D on amphibious ship flight decks closes LHD 6 HAR RISK MITIGATION.
APPROACH: NRL 6130 / SEA 05P2 tested qualified nonskids University of Dayton Research Institute (UDRI) / AIR 4.4
to determine if any products reduce risk of used laboratory air cannon test to simulate impact of nonskid
V-22 exhaust heat causing nonskid to crack/ chips on turbine blades to determine which nonskid chips
delaminate on flight deck. cause relatively less blade damage.
NRL 6130 tests simulates exhaust heat and deck UDRI tests fire nonskid chips in foam sabot at fixed aircraft
deflection due to thermal expansion and provide engine blades to rate relative impact damage.
relative cracking / delamination resistance.
What drove the MIL-PRF-24667 interim change?
Potential FOD Potential FOD
Vertical landing stirs up nonskid debris
Taxiing aircraft may ingest nonskid debris
Potential FOD
Potential FOD
Foam sabot with nonskid
Foam sabot
with nonskid
Blade on
bench
Distribution A: Approved for Public Release 16
LABORATORY
TEST RESULTS: NRL 6130 simulated V-22 exhaust heat cracking tests UDRI nonskid chip and turbine blade impact tests show lightweight
show lightweight, low density nonskid cracks/ low density nonskid causes less blade damage than conventional
delaminates less than 11 other conventional, nonskids. Composition G nonskids.
NEW REQUIREMENTS: MIL-PRF-24667C Interim Change defines Composition D, low density nonskid as containing only polymeric/crushed glass
aggregate with:
- Cured coating density: <0.66 lbs/ft2
- Aggregate blend density: 0.6 - 0.9 gm/cm3
- Maximum aggregate hardness: 6 Mohs
Update to FY-19 Standard Item 009-32 to require use of Composition D nonskid on LHA, LHD, LSD, & LPD flight decks.
Publishing Interim Change to MIL-PRF-24667C to define new Composition D nonskid and updating Standard Item 009-32 to require Composition D on
amphibious ship flight decks closes out 2017 LHD 6 HAR “Risk Mitigation” task to identify new materials that reduce aircraft engine damage.
What drove the MIL-PRF-24667 interim change?
Conventional nonskid
Thermal spray nonskid
Conventional nonskid Low density nonskid
Low density nonskids resist V-22 heat cracking/delamination and cause less turbine blade damage and
as such will be the first, qualified, Composition D nonskids
Low Density Nonskid
Distribution A: Approved for Public Release 17
What drove the MIL-PRF-24667 interim change?
TRANSITION TO FLEET SERVICE: Transition of Composition D products to Fleet service is in progress and requires:
1. Publication of Interim Change to MIL-PRF-24667C nonskid specification to define
Composition D nonskid requirements.
2. Update of ASSIST data base to include new Composition D qualified product database listing.
3. Update to the FY-19, Change 2, Standard Item 009-32 to require Comp D on amphibious ships.
STATUS: Interim Change to MIL-PRF-24667C to create new, Composition D complete, with SEA 05 concurrence, and submitted to
SEA 05S for publication on 7 Mar 2018 and includes:
Interim Change to MIL-PRF-24667C to define new Composition D nonskid is complete and listing on ASSIST database is pending.
3.2.6 Aggregate density (composition D only). When evaluated in accordance with 4.5.30, the aggregate blend density value shall be between 0.6 and 0.9 g/cm³.
3.2.7 Aggregate hardness (composition D only). When evaluated in accordance with 4.5.31, the maximum hardness value of any aggregate type tested shall not
exceed a rating of 6 on the Mohs scale.
4.5.30 Aggregate density (composition D only) The blend density of the aggregate shall be evaluated in accordance with ASTM D1895, method B. The
aggregate blend density shall meet the requirement of 3.2.6.
4.5.31 Aggregate hardness (composition D only) A random sample of 5 grams of aggregate shall be selected, and if comprised of multiple aggregate types
(e.g., polycarbonate and glass), separated by aggregate type. For each aggregate type, place a minimum of 3 grains of aggregate between two microscope slides.
While wearing appropriate safety gloves and applying considerable finger pressure, slowly move one slide over the other with a reciprocating motion for 10
seconds. Examine the glass surface and if not scratched, the aggregate shall be considered to have a Mohs value of 6 or less. Repeat for each aggregate type
previously separated. The samples shall meet the requirement of 3.2.7.
Distribution A: Approved for Public Release 18
What drove the MIL-PRF-24667 interim change?
TRANSITION TO FLEET SERVICE: Transition of Composition D products to Fleet service is in progress and requires:
1. Publication of Interim Change to MIL-PRF-24667C nonskid specification to define
Composition D nonskid requirements.
2. Update of ASSIST data base to include new Composition D qualified product database listing.
3. Update to the FY-19, Change 2, Standard Item 009-32 to require Comp D on amphibious ships.
STATUS: Interim Change to MIL-PRF-24667C to create new, Composition D requires update to ASSIST qualified products
database:
21 Mar 2018 – SEA 05P2 e-mail to International Paint and AST/ITW to contact SEA 05S via letter with
request to qualify products to Composition D “by extension”
31 Mar 2018 - NRL to submit short, letter report to SEA 05P2 on Intershield 5150LWT and
MS-4100G aggregate hardness and density.
20 Apr 2018 - SEA 05S to list new Composition D products on ASSIST qualified products database.
No new data required to update Composition D nonskid on ASSIST database, but product listing must follow required SEA 05S process.
Add TYPE I, COMP D line and list will show
Intershield 5150LWT and MS-4100G low
density nonskids.
Distribution A: Approved for Public Release 19
What drove the MIL-PRF-24667 interim change?
TRANSITION TO FLEET SERVICE: Transition of Composition D products to Fleet service is in progress and requires:
1. Publication of Interim Change to MIL-PRF-24667C nonskid specification to define
Composition D nonskid requirements.
2. Update of ASSIST data base to include new Composition D qualified product database listing.
3. Update to the FY-19, Change 2, Standard Item 009-32 to require Comp D on amphibious ships.
STATUS: Update to the FY-19, Change 2, Standard Item 009-32 to require Comp D on amphibious ships is complete and
will be submitted to CNRMC for publication by 31 Mar 2018.
New FY-19, Change 2, Standard Item 009-32, Table 2, Lines 16B & 16C requires LHA, LHD, LPD, and LSD flight decks use Composition D nonskid.
Only TYPE I, COMP D listing on
ASSIST database in near term
for Intershield 5150LWT and
MS-4100G low density nonskids
Distribution A: Approved for Public Release 20
ISSUE: Interior Deck Covering specifications are being revised and combined to reflect the recommendations for commonality
generated during the NAVSEA Deep Dive (CMN-003-2011-11).
APPROACH: Update the existing specification content to streamline outdated and inconsistent testing and qualification requirements,
remove unnecessarily expensive requirements to promote qualification of additional materials of high interest to the fleet, and
combine similar specs to reduce administrative and maintenance costs associated with each spec.
WORK COMPLETED:
1. MIL-PRF-32584, Deck Covering Materials, Monolithic
was published on 01 August 2017. The following
specifications for liquid deck covering materials
were incorporated into MIL-PRF-32584:
• MIL-PRF-32171
• MIL-PRF-24613
• MIL-D-3134
• MIL-D-21631
2. Qualification letters have been
sent to the manufacturers of
products qualified to the
legacy specifications for
qualification to MIL-PRF-32584.
Consolidation of Deck Covering Specifications
and Institution of Industry Standard Test Methods
Sweep deck clean
MCRRS
Distribution A: Approved for Public Release 21
WAY AHEAD:
1. COMPLETE AND PUBLISH draft specification
MIL-PRF-XX642, Deck Covering Materials,
Resilient Flooring, for the consolidation of
all solid deck covering materials.
2. REVISE MIL-PRF-3135, Deck Covering
Underlay Materials, to update legacy
requirements and test methods and
consolidate all underlay material
specifications.
Consolidation of Deck Covering Specifications
and Institution of Industry Standard Test Methods
Sweep deck clean
MCRRS
Distribution A: Approved for Public Release 22
Summary
- NAVSEA goal is to reduce coating life-cycle costs from application at
ship acquisition through to ship disposal.
- NAVSEA continually updates specifications and Standard Items to
address real issues encountered by the fleet.
- NAVSEA to continue efforts to streamline coating processes.
Distribution A: Approved for Public Release 23