Vehicle and Support Equipment T'O' Update

1
Vehicle and Support Equipment T.O. Update
2003 Air Force Corrosion Managers Conference

• Presented By
• Dave Ellicks, Materials Engineer,
  AFCPCO
• Michael Surratt

2
Overview

• Overall USAF corrosion cost 1.1B annually
• Corrosion - if left untreated
• Premature structural failure
• Increased maintenance downtime
• Reduced service-life
• Less equipment availability to the war fighter
• Vehicle and Support Equipment mission essential
• Corrosion Prevention and Control awareness and/or
  familiarization lacking
• NACE - 35 cost reduction/avoidance using
  existing materials and processes

3
Many Factors Affecting Corrosion
Poor/No Drainage Unprotected Crevices Dissimilar
Metals Finish Systems Materials
Selection Electronic Components
Materials Finishing Joining Processes Assembly
Processes Wet Installation of Fasteners Open Cell
Foam
Acquisition Reform Act
Operator Neglect Improper Repairs Inadequate
Corrosion Prev. Pgm. Inadequate Corrosion
Prevention Training/Tech Data
UV Resistance Breaks Around Fasteners Abrasion Imp
act Resistance Prev. Maintenance Frequency
Wide Range of Env. Air Quality Water Quality
Avail Authorized Sealing, Cleaning, Coating
Compounds Available Down-time
Condensation Water Intrusion Microbial
Growth Spillage
4
Project Support

• SAIC is on contract through the Air Force Support
  Equipment and Vehicle Management Directorate
  (WR-ALC/LEEV)
• WR-ALC/LE Equipment Specialists
• Corrosion engineering support provided by AFCPCO
• MAJCOM supplied inputs
• AGSEWG and VIWG in the coordination loop
• Review of DOD AGE Corrosion Prevention and
  Control guidance and successful engineering
  studies for acceptable materials and processes

5
Technical Guidance 36-1-191

• Technical And Managerial Reference For Motor
  Vehicle Maintenance
• Establishes the responsibilities and execution
  for a vehicle corrosion prevention and control
  program rests with the local installation
  commander and local vehicle managers
• Structural repairs referred to commercial repair
  manuals
• Limited guidance on Corrosion Prevention and
  Control in design, and/or maintenance
• Surrattism - TO does not give the commanders and
  fleet managers necessary information to establish
  a viable Corrosion Prevention and Control program

6
Concerns

• Designed-in Corrosion Prevention and Control
  usually cost more up front, but total life cycle
  cost analysis should be stressed to highlight
  cost savings/cost avoidance
• Effective Corrosion Prevention and Control
  results in life cycle cost savings generated from
  less down time for maintenance and cost avoidance
  in equipment replacement
• Acquisition activities have to choose more
  corrosion protection upfront or aftermarket
• USAF needs senior-leadership to advocate more
  effective designed-in Corrosion Prevention and
  Control in new acquisitions

7
Design Concerns
Side Supports Stakebed Truck
Cargo Loader Hand Rails
Forklift Window Seal Retaining Moisture
Sectionalized Rubber Window Seal
8
Design Concerns (Cont.)
Windshield Rubber Seal Open Edge Captures Fluids
Rain Gutter - No Outlet
Sand Dirt Accumulated in Recesses
Flat Storage Compartment Bottom
9
Design Concerns (Cont.)
10
Design Concerns (Cont.)
Wood installed w/o sealant/sealer
11
Design Concerns (Cont.)
Steel hinge bolted to aluminum skinned door
Dissimilar metals in the latch and exterior skin
12
Lack of Corr Prevention Awareness/Training
Cutout Replace
Secondary Damage
Finished Repair w/o Total Corrosion Removal
Bulging Effect
13
Lack of Corrosion Prevention Awareness
Required abrasive blasted to near-white metal
finish not achieved but was acceptable to the
unit
Corrosion underneath masked data plate
considered acceptable to the unit
14
T.O. Update Objective

• Give the local commanders and vehicle fleet
  managers the informational tools to be able to
  formulate and implement an effective Corrosion
  Prevention and Control action plan on all
  assigned vehicles

15
Technical Guidance 35-1-3

• Corrosion Prevention, Painting And Marking Of
  USAF Support Equipment
• AGE technicians assuming more Corrosion
  Prevention and Control responsibilities
• Organizations outsourcing/contract repainting -
  sometimes successful - sometimes not successful
• Coatings on new equipment acquisitions
  prematurely deteriorating, resulting in
  structural damage
• AGSEWG requested AFCPCO assistance in providing
  AGE specific Corrosion Prevention and Control
  guidance

16
Technical Guidance 35-1-3

• Task to update 35-1-3 materials and processes
• Merging T.O. 35-1-2 Compounds And Procedures For
  Cleaning Support Equipment
• Leverage past engineering study successes
• Reviewing other services AGE maintenance manuals
• Queried MAJCOM/Units for inputs
• New updated chapters will be coordinated through
  WR-ALC/LEEG and MAJCOM managers prior to
  finalization
• End result - AGE specific Corrosion Prevention
  and Control guidance designed for AGE maintainers

17
Summary

• Corrosion Control is an extremely costly
  sustainment/mission readiness problem
• AGE and Vehicle maintainers need better Corrosion
  Prevention and Control guidance
• VIWG and AGSEWG requested the AFCPCO provide
  support to the Air Force Support Equipment and
  Vehicle Management Directorate
• Currently, updating TO 36-1-191, combining and
  updating TO 35-1-3 and TO 35-1-12
• Technical order updates in progress estimated
  completion Sep 03

18
Project POCs

• Lead Engineers Mr. David Ellicks, AFRL/MLS-OLR
• DSN 468-3284, david.ellicks_at_robins.af.mi
  l
• Mr. Robert David, WR-ALC/LEEV
• DSN 468-7603 x 188 robert.david_at_robins.af
  .mil
• Support Contractor Michael Surratt, SAIC
• [phone]
  surrattm_at_saic.com