Bringing together developers, implementers, and users

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Welcome

• Bringing together developers, implementers, and
  users
• Coatings Removal
• Coatings
• Equipment
• Facilities

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Air Force Corrosion Preventionand Control
Program Overview11-12 May 2004

• Major Dan BullockChief, Air Force Corrosion
  Prevention and Control Office

DISTRIBUTION A. Approved for public release
distribution unlimited.
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Air Force Corrosion Preventionand Control Office
Mission Ensure the Air Force has an effective
program to prevent, detect, and control corrosion
and minimize the impact of corrosion on Air
Force combat capability.
Directed by HQ USAF Manage AF Corrosion
Maintenance Program (AFI 21-105, Air and Space
Equipment Structural Maintenance, Apr 03)

• Engineering and Technical Assistance
• Engineering Responsibility for 8 Technical Orders
• Corrosion Surveys of Major Commands, Weapon
  Systems
• Weapon System Corrosion Prevention Advisory
  Boards
• Host Annual USAF Corrosion Conference
• Support Corrosion Training
• Facility Requirements for Corrosion Maintenance
• Cost of Corrosion Studies
• Transition Corrosion Technologies to Users

Customers - Field Units - Major Commands -
System Managers - Air Logistics Centers - AF
Research Laboratory
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Respective Responsibilities

• AF Corrosion Prevention and Control Office
  (AFCPCO)
• AF-wide technical guidance, assistance,
  evaluation, and technology transition
• General-series technical orders
• System Program Offices (SPOs)
• Engineering authority for each system
• System technical orders
• Major Commands (MAJCOMs)
• Determine operational requirements
• Operate and maintain systems
• Air Logistics Centers (ALCs)
• Depot-level maintenance and modification
• Air Education and Training Command
• Train corrosion maintainers
• Air Force Research Laboratory
• Research and development program

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Current Coating-Related Efforts

• Update to AF paint/depaint technical order
• Hydrogen peroxide stripper qualification
• Metal wire arc spray on rocket launch towers
• PreKote authorization
• Modular powder coating system
• Completed paint gun cleaner evaluation
• Corrosion preventive compound evaluation
• Teamed with AF Research Laboratory on
• Roller application
• Plastic media specification revision
• Innovative non-chrome primer testing
• New rain erosion coating

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Technical Orders

• T.O. 1-1-8, Application and Removal of Organic
  Coatings,Aerospace and Non-Aerospace Equipment
• Complete update in work expect publication
  mid-2004
• Changes include
• Updated military specification references
  throughout
• National Stock Numbers for many products
• PreKote surface treatment as alternative to
  Alodine
• Dropped reference to plastic media
  recycling/leasing
• Dropped reference to conventional spraying

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Mobile/Modular Powder Coating Application
Facility (MOPAF)

• Prototype Modular/Mobile Facility for powder
  coating
• Primary function conventional thermal-cured
  powder
• Expanded capability conventional liquid
  coatings (current), UV-cured coatings (future)
• Stand-alone outdoor operation at selected sites
• Facility delivered to Lockheed for USAF programs
  installation/checkout/training completed Apr 04
• AFCPCO has not endorsed powder coatings for
  AF-wide aircraft use PC applicability is highly
  application specific, and requires engineering
  approval in each case

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Air Force Corrosion Facilities Reference Guide

• Existing guidance inadequate for corrosion
  maintenance operations
• Many existing facilities have deficiencies,
  resulting in inadequate maintenance of the
  aircraft, increased risk to personnel, and
  environmental non-compliance
• Commands cannot justify cost of adequate
  facilities

• AFCPCO completed Air Force Corrosion Facilities
  Reference Guide Mar 03 updated April 04
  publicly releaseable
• Documents capabilities needed to perform
  corrosion tasks (light, heating/cooling, airflow,
  filtration, power, etc.)
• Describes available ways to achieve those
  capabilities
• References existing regulations

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Environmental SeverityStudies

• Corrosivity data from over 100 locations
  worldwide
• 7075, 6061, 2024 aluminum, 1010 steel
• Flat panels, lapjoints, exfoliation
• Sensors now flying in C-130 and C-141 aircraft
• Used to establish aircraft wash frequencies,
  refine algorithms for corrosion prediction,
  understand corrosion progression structural
  effects

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New Chemical Paint Removers

• Continuing to evaluate hydrogen peroxide
  activated removers
• Better performance than other envir. compliant
  removers, same PPE
• Meet all performance requirements except for
  magnesium corrosion, pH, viscosity, evaporation
• AFCPCO approved for USAF use with restrictions
• Weapon system engineering authority must approve
• Depot-level use ONLY (not field units)
• Currently, must be used within 6 months

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New Chemical Paint Removers

• Two products in use
• New formulations being evaluated, with improved
  shelf-life and corrosion
• New Air Force-wide purchase description in work
  will include hydrogen peroxide type activated
  removers, with appropriate performance
  requirements

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New Projects

• Southwest Asia Corrosion Assessment
• Multiple AF locations in SW Asia and CONUS
• Detailed on-site inspections of weapons systems
  and equipment exposed to SW Asia environments
• Assessment of deployed maintenance capability
• Dust/soil samples for analysis
• Objective new T.O. processes/materials to reduce
  impact of corrosion in SW Asia

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New Projects

• Field Test/Authorization of Barrier Coating
• WR-ALC/Battelle barrier coating between primer
  and topcoat on aircraft to permit selective
  stripping
• Short-Term and Long-Term Packaging and Storage
  Methods
• Transition technologies to improve packaging of
  parts for shipment
• Exposure testing of vapor corrosion inhibitors,
  barrier storage products, and dehumidification

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Office of the Secretary of Defense Corrosion
Strategy

• FY 03 Defense Authorization Act DoD shall
  designate corrosion official, and develop
  long-term strategy
• Joint-service working group meeting with Office
  of the Secretary of Defense (OSD) since Apr 03
• New DoD policy
• Corrosion planning required for all acquisition
  programs
• Corrosion Prevention Advisory Team (CPAT)
  required for each program

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Outcomes

• DoD-wide Corrosion Web Site (www.dodcorrosionexcha
  nge.org)
• OSD-ATL received approval of Budget Change
  Proposal for 27M for FY 05
• Proposals in work in all Services
• Additional funding expected FY 06-11
• Training curricula for program managers,
  engineers, and maintainers in work
• Product qualification process in development
• New cost of corrosion studies AF study is
  underway

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Air Force Needs

• On-going Air Force Needs
• Coatings optimized for composite substrates
• Environmentally acceptable active inhibition
• Fuel tank coating and corrosion issues
• Improved coatings removal processes
• Improved corrosion preventive compounds

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For More Information
DSN 468-3284 478-926-3284 afcorr_at_robins.af.mil htt
ps//afcpco.robins.af.mil