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Air Force Corrosion Prevention and Control Office Coatings Related Pollution Prevention Efforts 23 Oct 2002

. Air Force Corrosion Prevention and Control Office. MissionEnsure the Air Force has an effective program to prevent, detect, and control corrosion and minimize the impact of corrosion on Air Force combat capability.. . . Customers:- Field Units- Major Commands- System Managers- Air Logisti

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Air Force Corrosion Prevention and Control Office Coatings Related Pollution Prevention Efforts 23 Oct 2002

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    1. Air Force Corrosion Prevention and Control Office Coatings Related & Pollution Prevention Efforts 23 Oct 2002 Major Dan Bullock Chief, Air Force Corrosion Prevention and Control Office

    2. Air Force Corrosion Prevention and Control Office Mission Ensure the Air Force has an effective program to prevent, detect, and control corrosion and minimize the impact of corrosion on Air Force combat capability.

    3. Air Force Corrosion Prevention and Control Office Leadership of the Air Force Corrosion Community Engineering Responsibility for 8 AF-Wide Technical Orders Engineering and Technical Assistance Corrosion Surveys of Major Commands and Weapon Systems Weapon System Corrosion Prevention Advisory Boards Host Annual USAF Corrosion Conference Evaluate Corrosion Control Technologies

    4. Powder Coatings Prototype line at Robins AFB, GA for validation on a/c fire extinguishers, gas bottles  Modular facility to test at Hill AFB on aircraft wheels Will operate parallel to existing line--test w/o impact to production Evaluating UV-cured powder coating process for aircraft wheels @ Randolph AFB, TX Selecting material, determining process parameters Evaluating available materials for field-level touch-up of powder coatings Repair capability necessary to deploy PC PC already in USAF use on vehicles and SE.

    5. Metal Wire Arc Spray Metal Wire Arc Spray (MWAS) --zinc/aluminum coating Commercial process: MWAS in use for antenna towers in AF Space Command Project to test feasibility on AF Space Command launch towers Implemented MWAS at Blue Grass Army Depot for AF bombs Prototyped on AF Cargo Loaders Supporting PACAF effort to sustain facilities at Guam and Kadena AB Japan

    6. X-It PreKote Field Testing X-It is a pre-paint surface treatment for aluminum Non-chromated, promotes adhesion Potential to replace Alodine chromated conversion coating In use at Ogden Air Logistics Center on F-16s; tested on T-38s More data needed before AFCPCO recommends AF-wide and incorporates in T.O. 1-1-8 (technical order for painting) Six-year test to provide confidence on more substrates Applied to two A-10’s (Davis-Monthan AFB, AZ and Pope AFB, NC) and 2 C-130’s (Little Rock, AR, and Puerto Rico) in 2001 Latest inspections Sep 02; excellent performance to date Weapon system program offices may authorize sooner if desired Testing begun on magnesium aircraft wheels and T-1’s All tests with chromated primer; any approval will be contingent on use of chromated primer

    7. ACC Corrosion Survey Surveyed Air Combat Command corrosion program Sep 02 Assess overall health of command program (equipment, processes, hazmart, T.O.s, training, QA, scheduling) -- NOT an inspection Coatings-related findings: Corrosion shops using proper materials Excellent condition of aircraft One exception; structural patches Recommend Sempens or brush/roller Some use of unauthorized paints, especially on ground support equipment

    8. New Chemical Paint Removers Purchase Description (PD) used by Warner Robins Air Logistics Center (WR-ALC) for non-chlorinated solvent type remover – primarily benzyl alcohol based Evaluating new hydrogen peroxide-based removers (lab and on-aircraft) better performance than other env. compliant removers, same PPE fails tests for magnesium corrosion, pH, viscosity, shelf life. AFCPCO approved for USAF use with restrictions: Depot-level use ONLY (not field units) Must be approved by weapon system engineering authority Must be used within 3 months DRAFT Air Force-wide version of PD in work; will include hydrogen peroxide type activated removers

    9. Our Emphasis is Performance Our primary concern is corrosion prevention and control, not environmental compliance Our metric: best performance while complying with environmental restrictions New materials and processes require: Disciplined, legitimate testing Anecdotal experience not sufficient Vendor claims not sufficient Environmental compliance alone not sufficient Technical order authorization Weapon system program office is final authority T.O.s available at www.robins.af.mil/ti/tilta/documents/TechOrd.htm

    10. For More Information… Major Dan Bullock AFRL/MLS-OLR daniel.bullock@robins.af.mil

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