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Highlights of NAVAIR s Efforts in Corrosion Control and Prevention

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Highlights of NAVAIR s Efforts in Corrosion Control and Prevention

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    1. Highlights of NAVAIR’s Efforts in Corrosion Control and Prevention

    3. 3 Army’s rotary wing fleet minus UH-1 [per COL Ward] and not including introduction of Commanche. “Commercial” is major passenger carriers only. (FAA did not supply historical fleet information.) Average age of medium and large aircraft of fleet of four largest freight carriers (FedEX, UPS, Emery and DHL) is 24.1 years.Army’s rotary wing fleet minus UH-1 [per COL Ward] and not including introduction of Commanche. “Commercial” is major passenger carriers only. (FAA did not supply historical fleet information.) Average age of medium and large aircraft of fleet of four largest freight carriers (FedEX, UPS, Emery and DHL) is 24.1 years.

    4. While the average age of the aircraft continues to rise, the average age of the maintainer does not.While the average age of the aircraft continues to rise, the average age of the maintainer does not.

    5. 5 CORROSION TRENDS CORROSION HOURS PER FLIGHT HOUR

    6. 6 INSPECTION TRENDS INSPECTION HOURS PER FLIGHT HOUR

    7. 7

    9. 9 Aircraft Corrosion Control and Prevention PROGRAM ELEMENTS

    10. 10

    11. 11 Goal: Address corrosion as a common Fleet issue and not a aircraft specific issue Characterization and documentation of corrosion problems, prevention practices required to reduce this readiness degrader. Ensure corrosion practices are in agreement with manuals. Comparative analysis of problem areas with trouble-free regions across fleet inventory will enable solutions to be transferred across PMAs. Corrosion Fleet Focus Team

    12. 12 Team Focus NAVAIR Fleet Transition of proven solutions across platforms Rapid Insertion of Mature Technology Increased Information Dissemination Elimination of Duplicate Efforts

    13. 13 Team Members

    14. 14 Team Approach National Team stood up in November 2001 Review/Identify/Assess/Plan/Act Review Aircraft Corrosion Control and Prevention Program FY99/FY00 Program Report (AIR-4.3.4) Engaged TYCOMs and NATEC MTs to ID Fleet Issues Meet with FST & 6.0 Reps on current status of highlighted issues of previous report and new areas Review commercial technologies & on-going Team efforts Develop POA&M and Engage/Initiate Efforts/Tasking Communication: Bi-weekly Teleconferences Twice yearly Off-site meetings Implementing Web Based Knowledge Management System Status reports Presentations Calendar Threaded Discussion board

    15. 15 FY02 Program Summary Team Approach in Three Areas: Cross Platform Technology Transition High Temp Coating CA1000 Sealant Magnesium Gearbox Coatings Rapid Multi-Platform Technology Insertion Cleaning Pad, Bristle Disc Pre-Val AvDec MIL-L-87177 Salt Away Mildew Remover Core Team Activities Miscellaneous Corrosion Issues Training

    16. 16 HIGH TEMPERATURE COATINGS

    17. 17 CA-1000

    18. 18

    19. 19 Magnesium Gearbox Coatings Objectives: Identify better protective coatings than conventional MIL-R-3043 permanent resin Tailor coatings to specific alloys (AZ91C, ZE41A, etc.); alloy heat treatment is a factor Status: Rockhard and Sermetel products are candidates Some of these coatings have already been incorporated into existing refinishing requirements for H-53 and H-60 programs Investigating applications for other programs

    20. 20 H-53 Magnesium Gearbox

    21. 21 FY02 Program Summary Team Approach in Three Areas: Cross Platform Technology Transition High Temp Coating CA1000 Sealant Magnesium Gearbox Coatings Rapid Multi-Platform Technology Insertion Cleaning Pad, Bristle Disc Pre-Val AvDec MIL-L-87177 Salt Away Mildew Remover Core Team Activities Miscellaneous Corrosion Issues Training

    22. 22 3M Cleaning Pads

    23. 23 Radial Bristle Disc (RBD)

    24. 24 PreVal™ AEROSOL TOUCH-UP PAINT SYSTEM

    25. 25

    26. 26 AvDEC Gasket Materials

    27. 27 MIL-L-87177

    28. 28 Mildew Removal

    29. 29 FY02 Program Summary Team Approach in Three Areas: Cross Platform Technology Transition High Temp Coating CA1000 Sealant Magnesium Gearbox Coatings Rapid Multi-Platform Technology Insertion Cleaning Pad, Bristle Disc Pre-Val AvDec MIL-L-87177 Salt Away Mildew Remover Core Team Activities Miscellaneous Corrosion Issues Training

    30. 30 Low Temperature Application Paint Fleet Issue Identified by AIRLANT and NATEC MTs COSSI Proposal for approximately $550K 509 Manual requires Painting Performed at Temperatures >60°F Below 60°F Paint Does Not Cure Properly Corrosion, Weather Resistance Properties Inadequate Poor Film Formation Most O- and I-Level Painting Performed in Geographic Areas with Temperature Below 60°F 30-40% of the Time Two-Year Development/Test Program Potential Cost Savings of $1.2M/Yr Due to Repaints and Corrosion Maintenance (4.2 Source) Joint Program with AF

    31. 31

    32. 32 FY02 AERMIP Effort CPC Fogging Objective: Develop Naval Aviation Strategy for use of CPCs These areas include: Sub-structure (cargo bay, cockpit, & nose); stub wings; tail pylon, radomes, rotordomes, etc. Consolidate independent Navy CPC efforts into a centralized strategic plan O-level D-level Tailored to specific aircraft requirements (Material & Application) This effort leverages lessons-learned from similar processes developed by the US Coast Guard, industry, & the Air Force New Programs Initiating (F/A-18, EA-6B, E-2/C-2, etc.)

    33. 33

    34. 34 Training Is training Adequate? Is training Consistent? Are curriculums updated in a timely manner? If Not, Why? How can we assist?

    35. 35 Team Success & Constraints Immediate Successes: Elimination of duplicative efforts on PreVal Validated PreWash lubrication requirement for C-130 Short Term Successes: Approval of PreVal and Wash Pads for Fleet Usage Demonstration of Salt Away inability to work for Naval Aviation Expected Long Term Successes: Transfer of Platform funded successes to other aircraft MIL-L-87177 Magnesium Gearbox Coatings CA-1000 Impediments: $$$$$$$ No efforts addressing Support Equipment No efforts addressing Weapons No efforts addressing avionics One addressing electrical connectors No organized team visits to the fleet Long list of unfunded airframe efforts

    36. 36 FY03 Planned Efforts Team Funded MIL-L-87177 Improved primers and topcoats for touch-up CA-1000 Wash Cycle Frequency NATEC Training Seal Caps Corrosion Kit Funded by others AvDec Mg Gearbox Sealant Rotary Cutter Corrosion Preventative Compounds

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