WRALC Powder Coating Project

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AIR FORCE CORROSION CONFERENCE 2003
WR-ALC POWDER COATING PROJECT
Presenters Joe Yochum SAIC David Ellicks AFCPCO
PRESENTED BY DAVID ELLICKS MICHAEL SURRATT
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Powder Coating Overview

• Project Background
• WR-ALC Powder Coating Project Description And
  Status
• Components Coated
• Old Process
• Results of Powder Coating Implementation

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Background

• Air Force Corrosion Prevention and Control Office
  (AFCPCO) Recognized The Value Of Powder Coatings
  For Select Applications.
• AFCPCOs Early Involvement With Powder Coating
  Integration At Kelly AFB TX And Corpus Christie
  Army Depot (CCAD)
• AFCPCO Taken The Engineering Lead To Assist The
  Transfer And Integration Of Powder Coating
  Technology In USAF

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Background (Cont.)

• HQ AFMC/LGP-EV Established The PCIWG To Utilize
  The Expertise Within The ALCs, AFRL, AFCPCO,
  Weapon System Offices, HQ AETC And Develop A
  Common Approach To Powder Coating Integration.
• PCIWG Developed Standardized Test Protocols For
  Powder Coating Testing Within The Air Force.

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WR-ALC Project

• AFCPCO And HQ AFMC/LGP-EV Initiated A Project To
  Introduce Powder Coatings At WR-ALC.
• WR-ALC/TIP Selected The Hydrostatic Test Shop,
  Building 150.
• Workload Includes Overhaul Of
• Life Raft Inflation, O2, CO2 and Nitrogen Bottles
• Flightline And Building Fire Extinguishers

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Components
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Old Process

• Walnut Shell Abrasive Coating Removal
• Visual Insp. For Damage, Including Corrosion
• Zinc Phosphate Pretreatment
• Varied T.O. Directed Primers and Topcoats
  Including Zinc Chromate (TT-P-1757), Lacquer
  (MIL-L-7178), Enamel (TT-E-489) And Epoxy Primer
  (MIL-PRF-23377) And Polyurethane (MIL-PRF-85285)
• Limited workspace, variable workload resulting in
  frequent backlogs

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New Process

• Same Coating Removal, Inspection, And
  Pretreatment Processes
• Powder Coatings Selected to Replace Liquid
  Coatings and Primers
• Lo-Temp Cure Epoxy Powder For Life Raft, O2, CO2,
  Nitrogen bottles, And Interior Fire Extinguishers
• Lo-Temp Polyester TGIC For Flightline Halon
  Bottles
• Lo-Temp Zinc-Rich Epoxy Corrosion Inhibiting
  Primer
• Project Completed September 02

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Robins AFB
Building 150 Powder Coating Installation
Drawing Not To Scale
Preparation Area
Mask/Demask Area
Curing Oven
Powder Coating
Booth
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Process Improvement

• Cleaner Operation
• Eliminates Zinc Chromate Primer Coating
• Eliminates Lacquer, Enamel And Polyurethane
  Primers And Topcoats
• Significantly Reduces HAZMAT And HAZWASTE
• Improved Workplace Environment
• Painting Turnaround Time Reduced From Days To
  Hours
• Elimination of Excessive Parts Backlog
• Improved Coating Performance

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Points of Contact

• Pgm Mgr Air Force Corrosion Prevention and
  Control Office -- [phone]
• Major Dan Bullock daniel.bullock_at_robins.af.mil
• Mr. David Ellicks david.ellicks_at_robins.af.mil
  
• Facility Project Lead -- Warner Robins Facility
  Process Engineering [phone]
• Mr. James Hager james.hager_at_robins.af.mil
• Contractor SAIC - Warner Robins -- (478)
  929-3932
• Mr. Doug Bruner brunerd_at_saic.com
• Mr. James Dean deanja_at_saic.com
• Mr. Michael Surratt surrattm_at_saic.com
• Mr. Joe Yochum yochumjo_at_saic.com

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Questions?