CORROSION PREVENTION AND

1

• CORROSION PREVENTION AND
• CONTROL SURVEY
• OF
• AETC
• 09 AUG 30 AUG 04

Briefer Richard Kinzie AFCPCO
2
OVERVIEW

• INTRODUCTION
• PROGRAMMATIC FINDINGS
• TECHNICAL FINDINGS
• RECOMMENDATIONS AND CONCLUSIONS

3
FOCUS

• AUTHORITY
• AFI 21-105, Air and Space Equipment Structural
  Maintenance
• PURPOSE
• Evaluation of AETCs corrosion program
• Assessment of condition of aircraft and equipment
  w/respect to corrosion, and materials processes
• Exchange of information and On-site technical
  assistance
• APPROACH
• Evaluation using AF and command instruction/T.O.
  guidance
• Emphasis on survey and not inspection
• Focus on sound corrosion control materials and
  processes while complying with environmental
  restrictions

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ITINERARY

• LUKE AFB 09 10 Aug
• ALTUS AFB 12 13 Aug
• LITTLE ROCK AFB 16 17 Aug
• COLUMBUS AFB 19 20 Aug
• TYNDALL AFB 23 24 Aug
• RANDOLPH AFB 26 27 Aug
• OUT BRIEF HQ AETC/LG 30 Aug

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TEAM MEMBERS

• MAJOR ROBERT REED CHIEF, AF CORROSION
  PREVENTION AND CONTROL OFFICE (AFCPCO), ROBINS
  AFB, GA
• MR. RICHARD KINZIE SURVEY TEAM LEADER, AFCPCO,
  ROBINS AFB GA
• SMSGT DAVID ALLEN -- AFCPCO, ROBINS AFB GA
• MR. MARK FOLEY -- SK TECHNOLOGIES, AFCPCO,
  ROBINS AFB GA
• MS RUTH JETT -- SK TECHNOLOGIES, AFCPCO, ROBINS
  AFB GA
• MSGT PABLO MORALES AETC STRUCTUAL MAINTENANCE
  MANAGER, RANDOLPH AFB, TX
• MSGT GREG AUSTIN AETC CORROSION MANAGER,
  RANDOLPH AFB, TX
• MR. JOSEPH LEONE AFRL/MLSA, WRIGHT PATTERSON
  AFB, OH
• MR. BILL HOOGSTEDEN AFRL/MLSSO (CTIO), WRIGHT
  PATTERSON AFB, GA

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SURVEY AREAS
AIRCRAFT MAINTENANCE AVIONICS
SUPPORT EQUIPMENT
HYDRAULICS VEHICLE MAINTENANCE
WHEEL TIRE BIOENVIRONMENTAL ENG
ARMAMENT ENVIRONMENTAL MGMT
MUNITIONS PLANS SCHEDULING
COMM-ELECT QUALITY ASSURANCE
OTHER TRAINING
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• PROGRAMMATIC FINDINGS

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PROGRAMMATIC FINDINGS

• COMMAND-WIDE PROGRAM
• Influenced by multiple factors
• Environment
• Types of maintenance organizations
• Operations
• Good but not institutionalized
• Support for Command Corrosion Manager
• GUIDANCE
• AETCI 21-106 instruction very good update in
  work
• Need for designated Wing Corrosion Manager
• Other suggestions for next update
• Local OIs varied from very good to nonexistent

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PROGRAMMATIC FINDINGS

• QUALITY ASSURANCE
• Critical function for effective program
• Involvement in corrosion processes varied widely
  between locations
• Surveillance methods must reflect the type of
  maintenance organization
• Need for focus on processes and not just product
• Need for involvement in acceptance inspections
• AIRCRAFT WASH SCHEDULING
• Most units had an outstanding program with few
  overdue washes
• TRAINING
• Many units using current training video though
  some used badly outdated sound-on-slide modules
• Need for locally specific content in training
  programs
• AETC EMPHASIS ON ENVIRONMENTALLY FRIENDLY
  MATERIALS AND PROCESSES

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PROGRAMMATIC FINDINGS

• IMPACT OF AIRPARK SUPPORT AT SOME LOCATIONS

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• TECHNICAL FINDINGS

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STRUCTURAL MAINTENANCE/CORROSIONCONTROL

• PERSONNEL
• Very knowledgeable and motivated
• Manning levels generally adequate
• MAINTENANCE ROLE
• Integrally involved in all corrosion efforts at
  most locations
• MATERIALS
• Good use of authorized paints, primers, Alodine,
  sealants
• EQUIPMENT
• Most shops very well equipped
• PMB cabinets in proper use
• FACILITIES
• Most locations have very good facilities,
  effectively utilized and maintained

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AIRCRAFT WASH

• WASH
• Facilities good at most locations
• Wash rack management effective
• Scheduling
• Very good in most locations
• Few overdue washes
• Cleaners/Materials
• Use of proper materials
• Recommend additional authorized cleaners for
  better results in some locations
• Recommend QA be involved in entire process

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AIRCRAFT WASH

• Specific Issues
• Local PPE
• Proper use of cleaners
• Washing prior to Iso/Phase in some locations
• Improved wash pads
• Spot Cleaning
• Proper materials
• Dilution

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AIRCRAFT PAINTING

• GENERAL CONDITION
• Good overall
• Some structural patches are not primed or painted
• STRIPPING
• OTHER COATINGS ISSUES
• Waxing
• Advanced Performance Coatings (APC)
• Barrier Coating
• Coatings durability
• Non-Chrome Systems
• RECOMMENDATIONS
• Use authorized touch-up kits on structural repair
  patches
• Use Brush and roller application, SemPens, and
  Clipaks as authorized in T.O.s for touch-up
• Request authorization for waxing leading edges of
  T-1/T-6

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AEROSPACE GROUND EQUIPMENT

• GENERAL CONDITION VERY GOOD
• PAINT PROGRAM
• Frequency
• Touch-Up
• PMB STRIPPING
• Need for capability at some locations
• Tracking of media usage for change out per TO

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AEROSPACE GROUND EQUIPMENT

• LARGE TAILSTAND CONCERN
• WASHING
• USE OF CPCS

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OTHER MAINTENANCE ACTIVITIES

• AVIONICS
• Use of CPCs
• New generation Sealants (Av Dec)
• MUNITIONS
• Trailers
• Missiles
• WHEEL AND TIRE
• ARMAMENT
• FLIGHTLINE
• OTHER

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AIRCRAFT

• APPEARANCE
• Fading of white on upper surfaces
• Dirt resulting from long wash cycles
• Sun Shade Program
• TRAINER AIRCRAFT
• T-1 T-6 T-38 T-43
• FIGHTER AIRCRAFT
• F-15 F-16
• CARGO AIRCRAFT
• C-5 C-17 C-130

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HAZARDOUS MATERIALS PROCESSES

• HAZMAT PHARMACIES
• Corrosion Programs best friend if properly
  operated
• - Model Program at Luke AFB
• Concerns with materials approval process and
  revalidation
• UNAUTHORIZED MATERIALS
• Aerosol Paints
• Corrosive RTV sealant authorized alternative in
  stock
• General Purpose (7930 Stock Class) cleaners being
  used for aircraft spot cleaning in some
  activities

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HAZARDOUS MATERIALS PROCESSES

• SHELF LIFE
• Many locations have outdated or improperly
  updated materials such as paints and sealants
• Shelf life update program allows extension of
  these materials per AFMAN 23-110
• PARTS WASHERS

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VEHICLES

• GENERAL CONDITION
• Good overall
• PAINT PROGRAM
• Well managed and effective, both in-house and
  contract
• Touch Up
• CLEANING PROCESSES
• Vehicle wash
• Parts cleaning

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ON-SITE TECHNICAL ASSISTANCE

• Materials
• Aqueous cleaning materials for parts washers
• Touch-up paint kits
• Sealant tapes for antenna mounting, electrical
  connectors, floor panels
• Additional approved aircraft wash soaps
• Cleaning solvents
• Wash frequency requirements for deployed
  locations
• AFCPCO web site -- contains comprehensive
  information for corrosion maintenance programs
• Many personnel using site
• Encouraged participation in Corrosion Prevention
  Advisory Boards, Air Force Corrosion Program
  Conference

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SUMMARY

• OVERALL EFFECTIVE PROGRAM
• Active Command Functional Management (MSgt
  Morales and MSgt Austin)
• UNIQUE AETC ENVIRONMENTS, OPERATIONS, AND
  MAINTENANCE ORGANIZATIONS OFFER BOTH
  OPPORTUNITIES AND CHALLENGES
• AREAS FOR EMPHASIS
• Assignment of Wing Corrosion Managers
• More QA involvement in corrosion programs with
  surveillance tailored to the type of maintenance
  organization
• Unauthorized materials/Shelf Life Program

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CONCLUSION

• AETC personnel have been extremely hospitable,
  motivated, and forthcoming with information in
  support of the AETC and AF Corrosion Programs
• Detailed information and guidance can be found on
  the AFCPCO website at https//afcpco.robins.af.mil