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    1. Field Touchup/Repair of Powder Coatings 2003 Air Force Corrosion Program Conference March 10 14, 2003 Dr. Douglas Neale NCI Information Systems, Inc. Mr. David Ellicks Air Force Corrosion Prevention and Control Office Robins AFB, Georgia

    2. Field Touchup/Repair of Powder Coatings Air Force Inventory Of OEM Powder Coated Equipment Continues to Increase Influence of success in commercial applications Performance Cost Environmental Compliance AF Depot Level Powder Coating Capabilities Are Emerging Hill AFB Robins AFB Tinker AFB Others

    3. Field Touchup/Repair of Powder Coatings Powder Coatings Encountered Thermosets polymer powders applied electrostatically and baked (250oF 450oF) Classes of powder chemistries for AF applications Epoxy very good physical/chemical performance for interior use (UV-sensitive) Polyesters very good physical/chemical performance for interior/exterior use TGIC Urethanes Selection based on performance requirements and application characteristics of the coating

    4. Field Touchup/Repair of Powder Coatings How to Repair When Flawed or Damaged? Requirements/expectations (depot and field) Repair process practicability Compatibility with existing powder coating Performance mechanical, chemical and corrosion resistance (durability) Appearance Production/depot sites Strip and re-coat entire part Touch-up (original process, aerosols, brush kits) Field sites Original process not practical Touch-up with available military/commercial materials

    5. Field Touchup/Repair of Powder Coatings Project Purpose: Develop Experience Base with Materials/Techniques for Field Repair of Damaged Powder Coatings Cleaning/preparation Coating materials Commonly available military/commercial products Innovative Application processes

    6. Field Touchup/Repair of Powder Coatings Project Elements Lab - relative corrosion performance screening Select common touch-up/repair coating materials Select simple application process/technique Evaluate relative corrosion performance Modified Q-Fog CCT-1 (common automotive standard) Cyclical corrosion 4 hrs salt fog, 2 hours dry-off, 2 hours humidity Down-select Field Environmental exposure of repaired coupons Florida Coastal Repair damaged support equipment

    7. Field Touchup/Repair of Powder Coatings Laboratory Screening Tests Powder coating materials selected Epoxy Polyester TGIC Urethane polyester Substrates clean Aluminum no pretreatment Steel iron phosphate Bonderite pretreatment Coupons supplied/prepared by commercial vendors Morton (Rohm & Haas) Sherwin Williams

    8. Field Touchup/Repair of Powder Coatings Laboratory Screening Tests (continued) Repair materials Common MILSPEC primers/tie-coats/topcoats Commercial topical pretreatments/VCI coatings UV-cured topcoats Direct-to-metal waterborne acrylic latex topcoats Urethane protective barrier tape

    9. Field Touchup/Repair of Powder Coatings Laboratory Screening Tests Repair Materials Solventborne primer / high solids topcoat Baseline: -23377, Type 1, Class C / - 85285, Type II -23377, Type 1, Class N / -85285, Type II Waterborne primer / high solids topcoat -85582, Type I, Class C2 / -85285, Type II Pretreat / high solids topcoat (-85285, Type II) Alodine 1132 Sanchem Safegard 6100C or 13150A T.O. 1-1-8 non-chromated epoxy tie coat Cortec VCI 386

    10. Field Touchup/Repair of Powder Coatings Lab Screening Tests Materials (cont.) Solvent-borne primer / water reducible topcoat -23377, Type 1, Class C /- 64159, Type II (Army CARC) -23377, Type 1, Class N / -64159, Type II (Army CARC) Waterborne primer / water reducible topcoat -85582, Type I, Class C2 / -64159, Type II (Army CARC) Pretreat / water reducible topcoat (-64159, Type II) Alodine 1132 Sanchem Safegard 6100C or 13150A T.O. 1-1-8 non-chromated epoxy tie coat Cortec VCI 386

    11. Field Touchup/Repair of Powder Coatings Lab Screening Tests Materials (cont.) Single coat Cortec VCI 386 UV-cure coatings (2 manufacturers) Stand-alone (no primer or pretreat) Over Alodine 1132 pretreatment Over Sanchem Safegard 6100C or 13150A Over Cortec VCI 386

    12. Field Touchup/Repair of Powder Coatings Lab Screening Tests Materials (cont.) Direct to metal acrylic latex (DTM) Stand alone (no pretreat) Over Alodine 1132 Over Sanchem Safegard 6100C or 13150A Over Cortec VCI 386 3M 8681 HS polyurethane tape over pretreat Alodine 1132 Sanchem Safegard 6100C or 13150A Cortec VCI 386

    13. Field Touchup/Repair of Powder Coatings Auxiliary Touch-up Coating Development Corrosion Office initiative Powders dissolved directly in environmentally compliant solvents (acetone, PCBTF) Brush/aerosol application of coating with matched chemistry Local thermal cure (heat gun, IR lamp) Coating produced, properties under investigation

    14. Field Touchup/Repair of Powder Coatings Lab Screening Tests - Coupon Preparation Powder coating removal in center band (PMB) Roughen bare metal and adjacent powder coating with polymer abrasive pad Isopropyl alcohol wipe Brush application of primer/pretreat and topcoat

    15. Field Touchup/Repair of Powder Coatings Lab Results General 640 hours 80 cycles, Modified CCT All Touch-Up Coatings Proved Chemically and Physically Compatible with Substrates/Powder Coatings Evaluated Abrasive Pad/Alcohol Wipe Provided Suitable Surface Prep (Coating and Substrate) Brush/Sempen Used for All Coating Application (Cosmetics Not Optimum) See Final Tech Report for Detailed Analysis

    16. Field Touchup/Repair of Powder Coatings Lab Results Quantitative Evaluation of Coating Systems Used for Repair Numerical Composite Rating of Performance Creepage General Corrosion Blisters MILSPEC Baseline Comparison: -23377 / -85285

    17. Field Touchup/Repair of Powder Coatings

    18. Field Touchup/Repair of Powder Coatings Field Tests Down-selected Candidates from Original Matrix New Coatings Identified After Start of Lab Tests Battelle Florida East Coast Test Site Repaired Damaged Coatings on Coupons 6 Month Exposure Evaluate Performance (Visual Quantitative) Corrosion penetration, creepage Blisters Coating appearance Test Analysis/Report Due in March, 2003

    19. Field Touchup/Repair of Powder Coatings Field Tests - Down-Selection from Original Matrix 1: -23377 Type I, Class C / -85285 Type II 2: -23377 Type I, Class N / -85285 Type II 3: -85582 Type I, Class C2 / -85285 Type II 8: -23377 Type I, Class C / -64159 Type II 9: -23377 Type I, Class N / -64159 Type II 10: -85582 Type I, Class C2 / -64159 Type II 15: VCI, Single Coat 24: Alodine / HS Polyurethane Tape 26: VCI / HS Polyurethane Tape 28: Alodine / Water-Borne DTM Acrylic Latex 30: VCI / Water-Borne DTM Acrylic Latex

    20. Field Touchup/Repair of Powder Coatings Field Tests - Added Coating Systems T1: DTM Acrylic Latex Primer / DTM Acrylic Latex Topcoat T2: DTM Acrylic Latex Topcoat (Two Coats, No Primer) T-3A: Zero Rust Primer (Aerosol) T-3B: So Sure (Aerosol) UV: UV Cured Liquid Applied at Manufacturer Facility Z: -23377 Type I, Class N / -85285 Type III ( 50 mg/l VOC)

    21. Field Touchup/Repair of Powder Coatings Damaged Test Coupon Configuration

    22. Field Touchup/Repair of Powder Coatings Field Test Results - Aluminum

    23. Field Touchup/Repair of Powder Coatings Field Test Results - Steel

    26. Field Touchup/Repair of Powder Coatings Conclusions Lab and Field All coatings used for touch-up were chemically and physically compatible with the powder coatings Scuff sanding and alcohol wipe provide good bonds Multi-component MILSPEC paint systems provide best performance available in small touch-up kits for field Non-chromated MILSPEC primers generally performed as well as chromated under MILSPEC topcoats HS polyurethane tape provides excellent protection UV cured liquid technology not ready for field Innovative powder/solvent not viable Powder coatings are not magic - current touch-up/repair procedures and techniques apply for powder coatings

    27. Field Touchup/Repair of Powder Coatings Questions?

    28. MOPAF

    29. MOPAF

    30. MOPAF PRAM PROJECT: TWO YEARS: SEPT 01 -? SEPT 03 PURPOSE: ACCELERATE IMPLEMENTATION OF POWDER COATING TECHNOLOGY INTO AIR FORCE MAINTENANCE ACTIVITY DEMONSTRATE CAPABILITY ON MAJOR PRODUCTION COATED COMPONENTS/EQUIPMENT PROMOTE ENVIRONMENTAL COMPLIANCE REDUCE/ELIMINATE HAZMATS, VOCS, HAZWASTES

    31. MOPAF PROJECT ELEMENTS: SURVEY/SELECT CANDIDATE PROCESS/STAKEHOLDER OGDEN ALC - PRIMARY OKLAHOMA CITY ALC - SUPPORT VALIDATE POWDER COATING PROCESS ON CANDIDATE APPLICATION AIRCRAFT WHEELS LANDING GEAR COMPONENTS DESIGN/BUILD/VALIDATE MODULAR FACILITY IN PROGRESS IMPLEMENT MODULAR FACILITY AT STAKEHOLDER SITE SUMMER-FALL 2003

    32. MOPAF PROCESS VALIDATION: MATERIALS: T-38 WHEELS - 2024 ALUMINUM ALLOY LANDING GEAR COMPONENTS 7000 SERIES ALUMINUM ALLOY (ACTUATOR) 4340 HS STEEL (STRUT - 260 KSI) COATING SYSTEMS COMPARATIVE PERFORMANCE TESTING SURFACE PREP WHEELS ANODIZED, PEENED/ANODIZED LANDING GEAR ALUMINUM ANODIZED LANDING GEAR STEEL CAD PLATE, IVD ALUMINUM BASELINE: -85582 TYPE I CLASS C2 / -85285 TYPE I POWDER TGIC POLYESTER (275OF CURE) SINGLE COAT -85582 PRIMER / P0WDER

    33. MOPAF COMPARATIVE COATING PERFORMANCE TESTS CORROSION: CCT, FILIFORM, B-117 TENSILE STRENGTH (ALUMINUM) 5 BAKE CYCLES FATIGUE (ALUMINUM) 5 BAKE CYCLES HYDRAULIC FLUID IMMERSION 3 FLUIDS GRAVELOMETER IMPACT @ ROOM, LOW TEMPERATURE TEMPERATURE SHOCK ABRASIVE RESISTANCE CLEANABILITY STRIPABILITY

    34. MOPAF EQUIPMENT SYSTEM DEVELOPMENT DESIGN BUILD PROTOTYPE DELIVER/ASSEMBLE HILL AFB* FAMILIARIZE AF MAINTENANCE PERSONNEL OPERATION/MAINTENANCE START- UP/VALIDATION INITIATE PRODUCTION OPERATION * FIRST ASSIGNMENT CONTINGENT ON SUCCESSFUL COATING PERFORMANCE TESTS

    37. MOPAF CURRENT STATUS MOPAF CONSTRUCTION MARCH 2003 COMPLETION COMPARATIVE COATING PERFORMANCE TESTS (@ CTIO) SPECIMEN PREPARATION: INITIATE MARCH 2003 CONDUCT TESTS: JUNE - AUGUST 2003 (ESTIMATE)

    38. MOPAF REVIEW: VERSATILE/TRANSPORTABLE MODULAR POWDER, CONVENTIONAL COATING APPLICATION FACILITY STAND-ALONE OPERATION AT A DEPOT OR FIELD SITE INSTALLATION WILL NOT DISRUPT EXISTING PRODUCTION OPERATIONS PROCESS VALIDATION PRIOR TO COMMITTMENT TO POWDER TECHNOLOGY INTEGRATION OR CHANGEOVER PRODUCTION USE DURING INTEGRATION/CHANGEOVER

    39. MOPAF QUESTIONS ??