NAVAIR Corrosion Prevention

1
NAVAIR Corrosion Prevention Control2-Component
Aerosols Other New Tools Air Force
Corrosion Conference 14-18 March 2005Macon, GA
2
Touch-Up Aerosol Primers and Topcoats
Objective Evaluate performance of commercial
off-the-shelf aerosol products conforming to Mil
Specs for touch-up painting. Find alternative to
epoxy topcoats used for touch up
(MIL-PRF-22570). Background Non-qualified
aerosol coatings used for touch up do not provide
adequate corrosion protection, weather
resistance, durability, nor are they resistant to
operational fluids. Used extensively by O- and
I- level maintenance activities, and IMC sites.

Status Phase I Product screening and corrosion
testing is complete. Phase II Implement
qualified 2-component aerosols. Revise
MIL-C-81352, adding QPL. Evaluate -81352 products
against spec.
Date 3/7/2005
POC Jack Benfer James Whitfield
3
Touch-Up Aerosol Primers and Topcoats

• 2-Component Aerosols
• Lab evaluation complete. Product spray
  properties and coating quality acceptable
• Logistics underway- NSNs in progress. To be
  implemented via -509 revision or IRAC. Expected
  to be available to fleet by end of April.

Date 3/7/2005
POC Greg Garrett
4
Touch-Up Aerosol Primers and Topcoats

• 1-Component Aerosols
• Assessment underway of primers topcoats
  separately and in combination.
• Assessment planned to be completed by end of
  FY05. Implementation decision in early FY06.
• Products being evaluated

Primers         TT-P-1757 Class C Zinc Chromate
Primer Aerosol         RLE 17802YBD Barium
Chromate Aerosol, Hentzen Prototype        
Barium Chromate Aerosol, Deft Prototype        
593X300 Strontium Chromate Aerosol (yellow),
PRC-DeSoto         599X300 Strontium Chromate
Aerosol (blue-green), PRC-DeSoto        
A-A-2786 Primer, Aerosol (non-chromate)        
MIL-PRF-23377 Type 1 Class C Epoxy Primer, Akzo
Nobel Aerosol Prototype Topcoats        
MIL-PRF-81352 Type I Acrylic Lacquer        
MIL-PRF-81352 Type II Alkyd (Hentzen
Prototype)         MIL-PRF-81352 Type III
Urethane (Deft Prototype)         Pacific West
Chemical (PWC) Aerosol         MIL-C-53039
Urethane, CARC (single-component)

Date 3/7/2005
POC James Whitfield/Jack Benfer
5
MIL-PRF-23377
Objective Evaluate new non-chromate products.
Revise spec to create new barium chromate Class
like MIL-PRF-85582 Background New non-chromate
primers show promising improvements in corrosion
performance over older technology. NAVAIR depots
do not use MIL-PRF-23377 Class C much because of
strontium chromate health issues compared to
barium chromate.

• Status
• Three non-chromate primers placed on QPL for
  MIL-PRF-23377 Class N
• Deft 02GN083 (Type I)
• Hentzen 16708TEP/16709CEH (Type I)
• Hentzen 17176KEP/16709CEH (Type II)
• NAVAIR authorization letter Ser
  AIR-4.9.7/7.4801, March 1, 2005 authorizes the
  use of these primers only for scuff sand and
  overcoat of existing paint systems on aircraft
  exteriors
• Spec revision for Ba-chromate class close to
  completion. Expected in FY05.

Date 3/7/05
POC Kevin Kovaleski
6
Paint Preparation System (PPS)
Objective Evaluate feasibility of PPS as a
replacement for poly stainless steel paint
spraying cups to reduce paint waste and solvent
usage for gun cleaning. Background PPS allows
paint, for touch-up applications, to be mixed and
sprayed from a disposable cup liner. Following
use, only the spray gun and adapter requires
cleaning.

Status Evaluation completed. NSNs assigned.
Included in 01-1A-509 revision due March 05.
Date 3/7/05
POC Luc Doan/Greg Garrett
7
Geographic Assessment
(Abbott and Kinzie, 2004)
Comparison of Corrosion Rate Data for Navy Sites
to Worldwide Distribution 1- Year Cumulative
Corrosion of 6061-T6 Aluminum
Navy/Marine Aviation and Air Force Land Sites
8
Geographic Assessment
Corrosivity Sensor (AF)
(Abbott and Kinzie, 2004)
Status NAVAIR land sites completed. Carrier
study underway (Switched to Nimitz in Dec. 2004).
Additional sensor installed on GUNSTON HALL on 5
Jan. 2005.
Carrier Exposure Rack on CVN 74
9
Wash Cycle Frequency
Objective Extend wash cycle from 14 to 28 days.
If successful, will be implemented on selected
F/A-18 squadrons with follow-on efforts linked to
geographic assessment. Background Twelve-month
effort commenced on 9/1/04 per F/A-18 FST
concurrence. Initial estimate of 20,000
maintenance man-hours saved if implemented for
F/A-18A/D at selected locations.

Status Monthly NALDA data (Prevention and
Treatment) collected for all reserve F/A-18s.
Six month trending analysis planned in March
2005. Initial feedback shows mixed results, i.e.
increased corrosion maintenance may outweigh
reduced wash man hours. Also, jets tend to look
worse/dirtier.
Date 3/7/05
POC Luc Doan, Tom Doughty, Freddy Pacheco
10
Radial Bristle Discs on HSS/Ti
Objective Authorize use of Radial Bristle Discs
(RBD) on High-Strength Steel (HSS) (e.g. nose
main landing gears, launch bars, and
tail/arresting gear assemblies) Ti for small
corrosion repairs and spot paint removals.
Background RBD were originally authorized only
for use on Aluminum and its alloys per IRAC No.
26. Not approved for Magnesium, composite
(including fiberglass), windscreens canopies,
or fuel cells/bladders.

Status IRAC No. 30 to NA 01-1A-509 Manual
authorizes use of the 3M Radial Bristle Discs on
HSS. Titanium in 509 revision. Mg evaluation
underway in FY05 through AMCOM/NAVAIR partnership.
Date 3/7/05
POC Jack Benfer Kevin Kovaleski
11
Mildew Remover
Objective Develop and implement aircraft mildew
removal kit. Validate performance of new
inhibited composition per Navy and Army
criteria. Background A corrosion-inhibited
mildew remover kit has been developed for use on
interior aircraft surfaces. This kit is being
supplied to Navy, Marine and Army Aviation
maintenance facilities.
Removal of Mildew from Interior Helicopter
Surfaces

Before
After
Status Authorized 7 Jan 05 via CNASC Ltr 4123
Ser 497000A/7.4786.
Date 9/18/02
POC James Whitfield
12
Magnesium Conversion Coating
Objective Develop an easy-to-use, pre-packaged
Mg conversion coating kit per AMS-M-3171, Type VI
(touch-up for Mg corrosion protection). Background
New kit available from Henkel Surface
Technologies- same company that makes the Alodine
Touch-N-Prep (TNP) pens, etc.

Status NA 01-1A-509 IRAC 32 issued July 2004.

Date 3/7/05
POC James Whitfield
13
Conductive Gaskets
Objective Implement conductive gaskets on EA-6B
and H-60 fleet in 2005. Planned start for F/A-18,
E-6, T-45 and others in late 2005 and
on. Background Surface mount antennas are highly
prone to corrosion due to bare metal surface
requirements for electrical conductivity. AvDEC
materials have demonstrated dramatically improved
corrosion resistance and ease of application

Corrosion damage on bare antenna mounts
Antenna mount using gasket
Status IRAC 7 to 16-1-540 issued 4/04 for use on
antennas/wicks. F/A-18 field demo completed.
Implemention on H-60 and E/A-6B fleet underway.
Others pending platform decision.
Date 3/7/05
POC James Whitfield Diane Kleinschmidt
14
F/A-18 Demo of Antenna Gaskets

• F-18C BUNO 164230? Gasket Install Date Nov
  2003? Hours flown during deployment 367.9?
  Deployment Dates Jan 20 2004 July 26 2004?
  Deployed with CVW-3 aboard the USS Geo.
  Washington, AOR included the Mediterranean,
  Red Sea and Persian Gulf ? Post deployment
  antenna inspection conducted 17 August 2004

? FLEET FEEDBACK The Avionics (WC-210)
supervisor, AT1 Boles, stated The antenna
gaskets made a significant difference in the
performance of the systems outfitted with this
technology. There were no corrosion related
discrepancies that affected these antennas during
the deployment, whereas we had to change nine
antennas on other squadron aircraft due to
corrosion.