Highlights of NAVAIR

1
Highlights of NAVAIRs Efforts in Corrosion
Control and Prevention
Air Force Corrosion Program MeetingMarch 10-14,
2003Macon, GA
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HARSH, CORROSIVEENVIRONMENT
The maritime environment directly impacts every
material and process selection for the Navys
advanced systems

• Stack gases/ engine exhaust
• White water
• Steam

• Salt air
• High humidity
• High and cryogenic temperatures

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Fleet-Wide Aircraft Age Trend
Air Force
Navy
Army
Commercial
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Naval Aviation -- People
Deployed worldwide Average age -- 19
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CORROSION TRENDSCORROSION HOURS PER FLIGHT HOUR

• Corrosion hours at O level increasing greatly
  in the 1990s
• Aircraft in highly corrosive environment such as
  SH-60B dramatically impacted by this trend

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INSPECTION TRENDSINSPECTION HOURS PER FLIGHT HOUR

• O level Inspections as reported by AV-3M
  reporting increasing per flight hour as aircraft
• Increases in phased maintenance requirements,
  service bulletins, etc drive additional scheduled
  maintenance

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Comparison of Average MMH/FH for Corrosion and
Inspection
O I Level Maintenance
30
25

20
MMH/FH
15
10
5
0
A/C 1
A/C 2
A/C 3
A/C 4
A/C 5
A/C 6
A/C 7
A/C 8
A/C 9
1983-1990
1991-1997
Corrosion cost continues to escalate as aircraft
age!
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Aircraft Corrosion Control and Prevention Program
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Aircraft Corrosion Control and Prevention
PROGRAM ELEMENTS
Fleet/FST
NADEPs
Industry
ST
Environmental

AC2P2 Requirements Definition Perform
Engineering Analysis/Assessments Eliminate Top
T/M/S Corrosion Cost/ Safety Drivers Apply Best
Practices and Lessons Learned Facilitate
Transition of Advanced Technologies Develop
AC2P2 Plans for IPTs/FSTs Establish AC2P2
Recommendation/Solutions Develop Priority
Proposals on Corrosion and NDI Provide
Training Interface
Deploy Results
AAIPT/AERMIP
GS Manuals
LES/LPS
IMC/PDM
ARI/CREI
TOC FNC
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Potential Sponsors

• Total Ownership Cost/FNC an ONR initiative for
  Corrosion Reduction Initiatives- includes
  coatings, applique, CPCs, sensors, NDI
• OMN funding ARI, CREI, AAIPT, NPRE and AERMIP
  - includes efforts on PAA core , CPCs, SCC,
  interior coatings, turbine seals, and several
  corrosion initiatives, including the Corrosion
  Fleet Focus Team.
• Environmental Programs APPTec, SERDP, ESTCP-
  focused on alternatives for hex chrome, cadmium,
  lower VOCs. etc.
• SBIR Programs supports innovative technology
  solutions such as diamond-like coatings, large
  scale applique removal, NDI and D-gun
  technologies.
• 6.1 and 6.2 Programs for future technology and
  solutions on coatings, composites, hydrogen
  embrittlement, Cr/Cd replacement , BMI corrosion,
  sensors, corrosion prevention techniques.
• MANTECH focuses on composite and metals for
  improved and cost effective manufacturing
  methods.
• Corporate Initiatives discretionary ST,
  dem/val and capital equipment procurement
  programs.
• PMA Support focus on near-term issues.
• CRADAs and Commercial Service Agreements-
  contracts that allow for joint development and
  implementation of technologies.
• Cooperative Relationships with industry, DOD
  agencies, FAA, DARPA, NASA, DOE, and others to
  bridge any technology gaps requiring major
  initiatives (AIM and Virtual Data Base for
  example)

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Corrosion Fleet Focus Team

• Goal
• Address corrosion as a common Fleet issue and not
  a aircraft specific issue
• Characterization and documentation of corrosion
  problems, prevention practices required to reduce
  this readiness degrader.
• Ensure corrosion practices are in agreement with
  manuals.
• Comparative analysis of problem areas with
  trouble-free regions across fleet inventory will
  enable solutions to be transferred across PMAs.

• Basis for Requirement
• Corrosion is 1 of top 5 MMH/FH Degraders and
  the prime cause of O-level maintenance.
• TYCOM OPNAV involvement in task prioritization
  to ensure Fleet needs being met.

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Team Focus

• NAVAIR Fleet
• Transition of proven solutions across platforms
• Rapid Insertion of Mature Technology
• Increased Information Dissemination
• Elimination of Duplicate Efforts

Improve Quality of Service
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Team Members
FLEET
Group Integration
Solutions
OPNAV
NATEC
Depots
NAWCs
NAVAIR
NAVAIR Depots NAVAIR PAX NAVAIR Lke
NATEC TYCOM
OPNAV James Whitfield Steve Spadafora
John Melin Dean Fetterman
AMC Ray Bryska (LANT) LtCol Terry Burns Jack
Benfer Kevin Kovaleski AMCS Tim
Moore (PAC) Luc Doan Suresh Verma
AMC Don Beasley (RES) Rachael
Santos Brian Gilp
Add in out-yearsNAVAIR Lakehurst SE NAVAIR
China Lake Weapons
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Team Approach

• National Team stood up in November 2001
• Review/Identify/Assess/Plan/Act
• Review Aircraft Corrosion Control and Prevention
  Program FY99/FY00 Program Report (AIR-4.3.4)
• Engaged TYCOMs and NATEC MTs to ID Fleet Issues
• Meet with FST 6.0 Reps on current status of
  highlighted issues of previous report and new
  areas
• Review commercial technologies on-going Team
  efforts
• Develop POAM and Engage/Initiate Efforts/Tasking
• Communication
• Bi-weekly Teleconferences
• Twice yearly Off-site meetings
• Implementing Web Based Knowledge Management
  System
• Status reports
• Presentations
• Calendar
• Threaded Discussion board

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FY02 Program Summary

• Team Approach in Three Areas
• Cross Platform Technology Transition
• High Temp Coating
• CA1000 Sealant
• Magnesium Gearbox Coatings
• Rapid Multi-Platform Technology Insertion
• Cleaning Pad,
• Bristle Disc
• Pre-Val
• AvDec
• MIL-L-87177
• Salt Away
• Mildew Remover
• Core Team Activities
• Miscellaneous Corrosion Issues
• Training

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HIGH TEMPERATURE COATINGS
Objective Transition AV-8B hi-temp primer for
potential application on E-2/C-2 Outer Wing
Panels (OWP). Background Paint coatings on
underside of E-2/C-2 OWP are degrading due to
exposure to hot exhaust. This occurs when wings
are stowed and engine is running.

Status Provided data for this drop-in
replacement technology to E-2/C-2 FST. Is being
considered for potential FY03 demonstration and
validation.
Date 7/11/02
POC Luc Doan
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CA-1000
Objective Investigate applications for CA-1000
for corrosion control. Background CA-1000 has
been successfully implemented as an alternate to
conventional polysulfide sealants for use on H-60
magnesium gearbox lugs. Results indicate better
corrosion resistance and improved maintainability.
H-60 Gearbox Lugs

Typical Corrosion Damage
No corrosion damage after one year in service
with CA-1000
Status Investigating H-53, AV-8B and other
program applications.
Date 8/8/02
POC James Whitfield
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Y453LFL CA-1000
Application on F/A-18 Some Corrosion noted and
performance issues for further study
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Magnesium Gearbox Coatings

• Objectives
• Identify better protective coatings than
  conventional MIL-R-3043 permanent resin
• Tailor coatings to specific alloys (AZ91C, ZE41A,
  etc.) alloy heat treatment is a factor
• Status
• Rockhard and Sermetel products are candidates
• Some of these coatings have already been
  incorporated into existing refinishing
  requirements for H-53 and H-60 programs
• Investigating applications for other programs

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H-53 Magnesium Gearbox
Rockhard 985-111-002
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FY02 Program Summary

• Team Approach in Three Areas
• Cross Platform Technology Transition
• High Temp Coating
• CA1000 Sealant
• Magnesium Gearbox Coatings
• Rapid Multi-Platform Technology Insertion
• Cleaning Pad,
• Bristle Disc
• Pre-Val
• AvDec
• MIL-L-87177
• Salt Away
• Mildew Remover
• Core Team Activities
• Miscellaneous Corrosion Issues
• Training

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3M Cleaning Pads
Objective Replace current cleaning pads with
new 3M Scotch-Brite 33 pads. Background New
pads significantly improve cleanability of
painted surfaces without altering gloss or
marring surface. Also, pads clean faster, have a
longer usable life and are compatible with
current approved cleaners.

Status Lab and field data verify that pads are
more efficient. 3M has NSNs and brochure for new
33 pads. Cost Savings analysis estimates 35K
savings in materials and 160,000 maintenance
hours per year.
Date 7/9/02
POC Kevin J. Kovaleski
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Radial Bristle Disc (RBD)
Objective Provide an alternative method to
chemicals, flap brushes, and grinding wheels for
spot stripping and corrosion repair. Background
Older chemical strippers are toxic newer
chemicals strip much more slowly. Mechanical
stripping causes surface roughening (metal
removal) and pretreatment removal resulting in
the potential for more corrosion initiation sites.

Traditional removal methods result in substrate
damage
RBD removes paint and corrosion without damaging
substrate
Status Discs transitioned to the Fleet via
NAVAIR 01-1A-509 IRAC 26, which includes NSNs.
Testing continues for use on other substrates,
including titanium, magnesium, and high-strength
steels. Other configurations are under
development for composite and fiberglass surfaces.
Date 7/9/02
POC Tom Doughty
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PreVal AEROSOL TOUCH-UP PAINT SYSTEM
Objective PreVal sprayers offer an alternative
method of applying approved mil-spec paints for
small touch-up paint repairs on
aircraft. Background Non-approved aerosol
coatings do not provide adequate corrosion
protection, weather resistance, and durability,
nor are they resistant to operational fluids.

Status Issue IRAC to NA 01-1A-509 Corrosion
Control Manual authorizing use of the PreVal
sprayers by mid November of CY02.
Date 10/18/02
POC Greg Garrett
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Corrosion Control Touch-Up Kit
L. Pre ValAerosol sprayer
K. One-component primer And one-component topcoat
L
K
O
J. Primerand Topcoat Sempens
J
O. Two-component polyurethane brush
or sprayable topcoat
N
P
M
M. Pre-moistened abrasive pads and
towelettes
N. Chromate conversion coating pen
P. One-component brush or sprayable
polyurethane topcoat
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AvDEC Gasket Materials
Objective AvDEC material is being evaluated as
an improved alternative to conventional antenna
mounting configurations Background Surface mount
antennas are highly prone to corrosion due to
bare metal surface requirements for electrical
conductivity. AvDEC materials have demonstrated
improved corrosion resistance and ease of
application

corrosion damage on bare antenna mounts
AvDEC gasket material has embedded wire mesh to
provide electrical continuity
Status Currently being evaluated for H-53 and
H-60 applications. FY03 efforts to expand to
other A/C applications
Date 7/9/02
POC James Whitfield
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MIL-L-87177
Objective Validate MIL-L-87177 as alternative
to VV-L-800 Background VV-L-800 requires
frequent reapplication to provide adequate
corrosion protection. MIL-L-87177 has potential
for being much more durable
P-3 Flap Screwjacks

Daily application of VV-L-800
Application 28 day cycle MIL-L-87177
Status Already validated on P-3 C-130
programs, effort for FY03 is to validate
additional implementation opportunities
Date 7/9/02
POC Jack Benfer
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Mildew Removal
Objective Develop and implement aircraft mildew
removal kit. Background A mildew remover has
been developed for use on interior aircraft
surfaces. This material, along with application
accessories, needs to be made available for fleet
maintenance activities.
Removal of Mildew from Interior Helicopter
Surfaces

After
Before
Status Currently working with fleet activities
to evaluate prototype kit.
Date 9/18/02
POC James Whitfield
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FY02 Program Summary

• Team Approach in Three Areas
• Cross Platform Technology Transition
• High Temp Coating
• CA1000 Sealant
• Magnesium Gearbox Coatings
• Rapid Multi-Platform Technology Insertion
• Cleaning Pad,
• Bristle Disc
• Pre-Val
• AvDec
• MIL-L-87177
• Salt Away
• Mildew Remover
• Core Team Activities
• Miscellaneous Corrosion Issues
• Training

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Low Temperature Application Paint

• Fleet Issue Identified by AIRLANT and NATEC MTs
• COSSI Proposal for approximately 550K
• 509 Manual requires Painting Performed at
  Temperatures gt60F
• Below 60F Paint Does Not Cure Properly
• Corrosion, Weather Resistance Properties
  Inadequate
• Poor Film Formation
• Most O- and I-Level Painting Performed in
  Geographic Areas with Temperature Below 60F
  30-40 of the Time
• Two-Year Development/Test Program
• Potential Cost Savings of 1.2M/Yr Due to
  Repaints and Corrosion Maintenance (4.2
  Source)
• Joint Program with AF

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E-2C Hawkeye CPC Application Areas
Interior of Horizontal Stabilizer with Corrosion
X Aviation
Interior of Outer Wing Panel with Corrosion X
Aviation
Inboard and Outboard Fins with Corrosion X
Aviation
Relief Tube Areas with Corrosion X Aviation

• Under Floorboards-Bilge Areas with Dinitrol AV-15

Need to Match Material to Application
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FY02 AERMIP EffortCPC Fogging

• Objective Develop Naval Aviation Strategy for
  use of CPCs
• These areas include Sub-structure (cargo bay,
  cockpit, nose) stub wings tail pylon,
  radomes, rotordomes, etc.
• Consolidate independent Navy CPC efforts into a
  centralized strategic plan
• O-level
• D-level
• Tailored to specific aircraft requirements
  (Material Application)
• This effort leverages lessons-learned from
  similar processes developed by the US Coast
  Guard, industry, the Air Force
• New Programs Initiating (F/A-18, EA-6B, E-2/C-2,
  etc.)

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P-3 IFT Corrosion Issue
Concern over MIL-PRF-87260 Foam Inserts in Wing
Fuel Tank
3 Aircraft identified with Problem (Investigating
Source of Corrosion)
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Training

• Is training Adequate?
• Is training Consistent?
• Are curriculums updated in a timely manner?
• If Not, Why?
• How can we assist?

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Team Success Constraints

• Immediate Successes
• Elimination of duplicative efforts on PreVal
• Validated PreWash lubrication requirement for
  C-130
• Short Term Successes
• Approval of PreVal and Wash Pads for Fleet Usage
• Demonstration of Salt Away inability to work for
  Naval Aviation
• Expected Long Term Successes
• Transfer of Platform funded successes to other
  aircraft
• MIL-L-87177
• Magnesium Gearbox Coatings
• CA-1000
• Impediments
• No efforts addressing Support Equipment
• No efforts addressing Weapons
• No efforts addressing avionics
• One addressing electrical connectors
• No organized team visits to the fleet
• Long list of unfunded airframe efforts

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FY03 Planned Efforts

• Team Funded
• MIL-L-87177
• Improved primers and topcoats for touch-up
• CA-1000
• Wash Cycle Frequency
• NATEC Training
• Seal Caps
• Corrosion Kit

• Funded by others
• AvDec
• Mg Gearbox
• Sealant Rotary Cutter
• Corrosion Preventative Compounds