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2005 USAF AFCPCO Conference Update

Aerospace Paint Process. PreKote ReplacesAlkaline wash and cleaningAcid deoxidizingH3PO4, HF, HNO3 Chromate conversion coatingsSolvent wipe and cleaning use. Largest Source of Coating Failure: Poor Surface Pretreatment. PreKote

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2005 USAF AFCPCO Conference Update

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    1. 2005 USAF AFCPCO Conference Update

    3. Largest Source of Coating Failure: Poor Surface Pretreatment

    6. PreKoteŽ – 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

    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

    9. Cleaning / Metal Oxide Removal

    10. Cleaning / Metal Oxide Removal

    11. Cleaning / Metal Oxide Removal

    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. PreKoteŽ 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

    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. 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 S&R 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

    30. PreKoteŽ Environmental Closed Loop Reduce human exposure and environmental impact Improve downstream manufacturing processes Reduce extraction of earth’s 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@pantheonchemical.com www.pantheonchemical.com

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