2005 USAF AFCPCO Conference Update

1
2005 USAF AFCPCO Conference Update
2
Aerospace Paint Process

• PreKote Replaces
• Alkaline wash and cleaning
• Acid deoxidizing
• H3PO4, HF, HNO3
• Chromate conversion coatings
• Solvent wipe and cleaning use

3
Largest Source of Coating FailurePoor Surface
Pretreatment
4
(No Transcript)
5
(No Transcript)
6
PreKote Cr(VI) Reduction Technology

• Total systems approach
• Cleans substrate surface
• Modifies surface energy and surface tension
• Multifunctional molecules draw paint into
  substrate and flow over embedded contaminants
• Adhesion promoting molecules
• Molecules increase paint-to-substrate bond
• Effective with non-chrome and chromate conversion
  coatings

Before PreKote
After PreKote
7
Proven Non-Chrome Pretreatment System

• All metal substrates prior to priming, painting
  and metal-to-metal bonding
• Al, Mg, Ti, Cd plate, steel
• All composite substrates
• Cleaning and adhesion promotion
• Multiple application processes
• Manual, spray, power washer and immersion
• Non-corrosive, non-flammable, non-toxic, CFC
  free, ODS free and odor free
• Readily biodegradable

8
Cleaning / Metal Oxide Removal
Every coating operation requires pretreatment
9
Cleaning / Metal Oxide Removal
PreKote is used as part of the cleaning and
deoxidizing of the aircraft exterior
10
Cleaning / Metal Oxide Removal
Other surface pretreatments require acid
deoxidizing step used prior to use
11
Cleaning / Metal Oxide Removal
PreKote fits into any process by SPO choice
12
Compliance with AFI32-7086

• 1 November 2004, Chapter 3, Section 3, Purpose
• Weapon System Hazardous Materials Program
  describes how MAJCOM HMMP, MAJCOM weapon systems
  Requirement Offices to identify, prioritize,
  validate, advocate for, and fund weapon
  system-driven HAZMAT reduction needs.
• Section 3.2 Objective The overall goal is to
  reduce weapon system HAZMAT usage, consistent
  with mission accomplishment, with minimal TOC,
  and within acceptable levels of risk.

13
Military Laboratory Testing

• Laboratory results by USAF
• Confirmed SYSTEM performance met or exceeded
  standards
• Met Mil-Spec corrosion testing
• Met Mil-Spec adhesion testing
• Met Mil-Spec flexibility testing, exceeded
  chromate conversion coating
• 2001 Boeing Mesa product validation lab tests
• Considered baseline for non-chrome surface
  pretreatment studies

14
PreKote Cost Savings

• Reduced costs in every application
• Eliminated hexavalent chromium
• Eliminated alkaline wash and acid deoxidizer
• Environmental waste disposal
• Waste water treatment
• Personal protection equipment
• Healthcare costs
• Labor time
• Masking and process steps
• Cadmium leaching

15
In-Flight Validation

• First and only USAF-approved, non-chrome
  pretreatment for the replacement of chromate
  conversion coatings (such as Alodine 1200S)
• Use of PreKote mandated by USAF Training Command
  which logs more than 500,000 flight-hours per
  year
• T.O. 1-1-8 authorized with 2 conditions
• Deployed on the Boeing AH-64 Apache Helicopter
  for the US Army

16
(No Transcript)
17
AETC In-Flight Validation

• 1995 Magnesium gear boxes
• 1996 USAF AETC 500 aircraft to date, 2003
  mandate for AETC implementation
• T-37, T-38. T-1 -23s
• 30 - 45 man-hours saved per aircraft (T-1,
  T-37, T-38s)
• Source ProAct Air Force Center for Environmental
  Excellence Cross Talk
• 58,000 per year and 141,000 lbs of hazardous
  waste
• Source Sheppard Senator, Sheppard Air Force Base

18
AETC 2005

• T-6 PreKote trial
• Full non-chrome system in-flight testing

19
AFCPCO In-Flight Validation

• 2001 2 C-130s / A-10s in USAF sponsored test
• 2004 T.O. 1-1-8 approval

20
ACC In-Flight Validation

• 1997 F-16s with 1200 flying, 25 scuff sanded
• 19.4 man-hours saved per F-16 3,880 hours
  annually
• Source F-16 IDEA Program Submission
• 6,000 saved per F-16 1,200,000 per year
• Source Monitor Aeronautical Systems Center 2004

21
ACC In-Flight Validation

• 2003 and 2004 B-52 applications and inspection
• 1 full strip, 1 scuff sanded
• Implemented on escape hatches at Barksdale

22
ACC In-Flight Validation

• 2004 4 B-1Bs
• 1 full strip and 3 scuff sanded
• 2005 Full Implementation

23
ACC E-3s

• 2004 50/50 E-3B and inspection
• 2005 Second complete E-3B

24
A-10 Full Implementation
25
ACC Testing

• F-17 off aircraft parts
• U-2 paint system testing

26
ACC No Activity

• F-15
• F-22
• B-2
• SR Helicopters
• Commander Solo/Compass Call

27
AMC 2003

• KC-135 test vs. chromate conversion coatings
• 2 inspections

• No Activity
• C-17
• C-5
• VIPSAM
• KC-10

28
US Army In-Flight Validation

• 2002 Boeing Mesa (Apache) field tests begin
• 2005 Boeing specification approval
• Surface reactivation, magnesium gear boxes,
  repaint process

29
Government Recognition Awards
Pantheon Chemical (PreKote Surface
Pretreatment) Recognition Design for the
Environment (DfE)
Hill Air Force Base Awarded EPA Environmental
Excellence Award
Sheppard Air Force Base Nominated White House
Closing the Circle Award
Sheppard Air Force Base Nominated Texas
Environmental Excellence Award
30
PreKote Environmental Closed Loop

• Reduce human exposure and environmental impact
• Improve downstream manufacturing processes
• Reduce extraction of earths non-renewable
  resources from upstream activities
• Overall risk minimization due to in-flight
  performance record as a part of the coating
  system versus specification testing

31
Thank You

• For more information please contact
• David Palermo
• 888.608.7888
• dpalermo_at_pantheonchemical.com
• www.pantheonchemical.com