Corrosion Control Program

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Corrosion Control Program

• CWO Paul Cassese

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• U.S. Coast Guard Aircraft

HH6035 Aircraft8 Air Stations
HU2524 Aircraft6 Air Stations
Total Aircraft 178 Total Air Stations 36
HH6595 Aircraft17 Air Stations
HC13024 Aircraft5 Air Stations
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Coast Guard Aging Aircraft
1970
2040
C-130
HH-65
HH-60
HU-25
1970
1980
1990
2000
2010
2020
2030
2040
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New Deepwater Assets
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Coast Guard Corrosion Program Goals
Where the Rubber Meets the Road

• Identify and Implement Real Time Corrosion
  Mitigation Initiatives.
• Introduce State-of-the Art Technology.
• Institute a Continuing Comprehensive Corrosion
  Training Program.
• Establish an Extensive Corrosion Mapping Program.
• Cultivate an Aggressive Corrosion Preventative
  Advocate Program.
• Construct Environmental Severity Indices.
• Implement a Dehumidification Program.
• Drive PDM and MPC Schedules.

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Corrosion in Coast Guard Aviation

• Age of Aircraft
• Environmental Severity
• Operational Demands
• Remote Deployments
• Hanger Deck Experience Level
• Rescue Swimmer Ops
• New Deepwater Challenges

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Corrosion Prevention Advocate
Drives the Air Station Corrosion Program

• Ownership
• Prime Duty
• Billet (E7/E6)
• Water Testing
• Provide Training
• Approved Chemical List
• Station TIMI / Eng Instruction
• Report Directly to Engineering Officer

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Maintenance Procedure Cards
Corrosion Data Capture Tools

• Dedicated Corrosion MPC
• Un-tracked Corrosion (530000)
• Electronic Aircraft Logbook
• 50,000 Corrosion Repair hours
  
  FY 01-04

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Logistics Compliance Inspections
Ensure Your House is in Order

• Evaluate Effectiveness of Corrosion Control
  Program
• CPA Involvement
• Engineering Instruction
• Adherence to Process Guide
• Aircraft Inspections

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Water Analysis

• Tested Semi-Annually by CPA
• Aircraft Computerized Maintenance System (ACMS)
• Dissolved Solvents lt 500 ppm
• Chlorides lt 50 ppm
• pH 6 - 8
• MPC GS 159001.0

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Aircraft Cleaning
Most Effective Tool in Preventing Corrosion
Required Hot Water (120-140 Degrees) Foamers

• C-130
• Wash 2 Weeks (Flap/Wheel Wells)
• Wash Monthly (Fuselage
• HU-25
• Wash Weekly
• Rinse Daily (Engines)
• HH-60
• Wash Daily 14 Day Detail Inspection
• Rinse 50 Salt Water Hover
• HH-65
• Wash After last flight of day/Post Flight
• Rinse Flights below 500 feet
• Wash For 7, 14, 30 inspections

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Corrosion Prevention Compounds
C-130 ACF-50 Fogging airframe application /
Amalgard HH60 / HH65 Fluid Film - Fogging w/
Liquid A HU-25 Mil-C-81309 Type 1 - Fogging New
Revision MIL-C-81309 Mil-C-85054
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Corrosion Training
Aircraft Corrosion Control - Pensacola FL. (Air
Force) Course Code 500783 (Resident and
Exportable) Advanced Composite Technology -
Sparks, NV Course Code 140200
(Resident and Exportable) Aging
Aircraft Corrosion Control (Fills requirement
for Corrosion Process Guide)
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Environmental Severity

• Ongoing Evaluation
• Weight loss coupons
• MPC (1 2 year intervals)
• Corrosion Prediction model
• Gage Maintenance Staff
• Anticipate PDM efforts
• Vigilance / False sense of security

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Corrosion Mapping

• Physical Airframe Inspections
• Target Specific Grid/Zones
• Currently Depot Only
• ACMS - ALMIS Data Base
• Pictorial Data Views

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New Product or Process Approval

• Aeronautical Engineering Maintenance Management
  Process Guide CGTO PG-85-00-110
• Evaluation and Service Testing of Materials and
  Processes Prior to Application On Coast Guard
  Aircraft
• New material or process not qualified to a
  military spec, Federal Test Method, American
  Society for Testing and Materials (ASTM) Method
  Standard or other recognized standard is
  introduced by a manufacture for it intended
  purpose it is essential that necessary tests be
  performed and results properly analyzed to
  ascertain its suitability and adaptability to
  the particular application to include
  performance, quality, and reliability
  requirements.
• Manufactures Application for Introduction of
  Materials and Processes
• 
  
  
  (Enclosure 10)
• Technical Performance
• Supportability
• Cost
• General Considerations
• http//www.uscg.mil/hq/arsc/Contracting/GUIDE.HTM
  

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Dehumidification

• Why use Dehumidification? Reduction in
  Relative Humidity (moisture) A dry airframe is
  a happy airframe

MTBF greatly reduced with humidity levels below
50
Rate of corrosion1
CG Units average annual humidity range
Houston
Cape Cod
Relative weight loss
Corrosion STOPS
0 25 50 75 100
Relative Humidity
1 Vernon, W. H. J. (1926).
2 Sandia National Laboratories
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DehumidificationEfforts

• Site assessments complete at all CG Prime Units.
• Requirements
• Ease of use On /off in 5 minutes
• Lower relative humidity in 1 hour to at or below
  40 RH
• Hanger / ramp operations
• Temperature / Relative Humidity
• C130/HH60 Elizabeth City, NC
• HH65 Atlantic City, NJ
• HU25 Mobile Alabama
• Delivery of Units anticipated in 3 months

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AvDec Products Gasket / Tape

• HH65-
• Floor boards / antennas / cannon plugs
• Increasing inspection intervals
• HH60-
• Forward Bridge Mount /Side Trans.
• Mount /Floor boards / FLIR-TCAS/antennas
• HU25-
• Antenna / Entrance Door/Wing Panel
• (HT3000 Tape)
• C130 Antennas / Chemical Toilet (SLG)

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Two Part Polyurethane

• System
• Primer AKZO Nobel
• Topcoat US Paint (Gloss)
• Evaluated by Prime Units
• CG intention to incorporate into fleet
• Activate activator by pressing valve on underside
  of can 2-3 seconds.
• Mix by shaking for 3-5 minutes
• Adjustable spray valve- Vertical or Horizontal
• 24 Hour Pot Life

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Partnership Industry Sister Services

• Ongoing relationship with Joint Council of Aging
  Aircraft (JCAA) provides unique opportunities
  through Corrosion Steering Group (CSG)
• Funding for HH60 Avdec gaskets
• Funding for magnesium coating evaluation
• Interaction with Office Secretary Defense (OSD)
• Guidance through a focused corrosion Team effort
• Air Force Corrosion Office / NAVAIR / Army

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Control or Prevention
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Control or Prevention
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Control or Prevention
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No Magic Bullet

• Basic Maintenance Practices
• Ownership / Buy In
• Attention to detail
• Pride in your efforts

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Questions?

• CWO Paul Cassese Corrosion Program Manager
  
• (ph) 252-335-6953
• (fax) 252-334-5034
• (email) pcassese_at_arsc.uscg.mil