Alternative Coatings For Missile Launch & ICBM Support Presenter: Mr. Dave Ellicks - AFCPCO Mr. John Bloyer – SAIC Mr. Michael Surratt - SAIC Past Related SAIC Alternative Coatings 1995 Kadena AFB 1998 Guam Automated Metal Wire Arc Alternative Coatings on Vehicles: Spray (MWAS) refurbishment MWAS, Zinc Rich Epoxy, line on MK 82, MK 84 GP Inorganic Zinc, Ceramic loaded Bombs Epoxy, Rust Converters, 1996, 1997, & 2002 Kelly AFB, Corrosion preventatives CCAD, & Robins AFB 1999 Patrick AFB Powder Coating Evaluation and MWAS on Non-powered SE Systems Integration 2001 JG-PP Project 1997 Robins AFB Alternative Coatings On DOD Wing Maintenance Stands: and NASA SE Alternative Coatings - MWAS Project Team Members AFCPCO: Dave Ellicks HQ AFSPC: Rich Bliss SAIC • Northrop Grumman: Bruce • John Bloyer - Fong Materials/Corrosion Engineer • 90 MMXS / MMXFC • Joe Yochum – Mechanical Engineer • 341st Space Wing • Michael Surratt –Senior • 91st Space Wing Corrosion Analyst • 576th Space Wing • James Dean - Senior Corrosion Analyst • 41st Space Wing • John Lindsey - Senior • 2nd SLS Corrosion Analyst • EG&G Technical Services, • Karl Plaume – Corrosion Jacobs Sverdrup, Phoenix Analyst Management Inc MWAS Sprayed Metal Is Sacrificial Uses The “Throwing Power” Of Zinc On Steel Surfaces To Bridge Minor Damage 25+ Year “Lifetime” Coating with Extensive Documented Commercial Field Data Mature Technology 50+ Years Of Test Data Metal Wire Arc Spray (MWAS) Zero VOC Application Proven Most Durable 50+ Year History of Field Applied Coating Exposures Available Wires for Not Degraded by UV Cathodic protection of Steel High Deposition Rate With Twin Wire Electrode Aluminum Process Zinc Able to Spray Any Metal 85-15 Zinc/Aluminum in Wire Form Barrier Protection Resist High Temperatures Non-Slip Coatings Sensitive To Mis-Prep Task Description: Phase 1 Develop Acceptable, Effective Metallizing Preparation/Application Process Optimization On Rocket Launch Towers Metallizing Being Accomplished Now Metallizing Requires Specific Preparation Or The Corrosion Inhibiting Value Is Diminished Proper Surface Prep The Major Lim/Fac In Tower Metallizing Application Validate If (Alternative coating processes / Metallizing are effective for application environments) Metallizing Is Cost/Env Effective On Rocket Launch Equipment Field Operational Test, Dem/Val Of Now-Term Coating Removal On Rocket Launch Equipment (Facilities) Task Description – Phase II Field Operations Testing/Dem-Val Procure Equipment And Apply – Remove Materials From Select Sections Of Launcher/Launcher Support Equipment, ICBM Equipment Conduct Modified Coating Surface Preparation, Material Application Familiarization and Equipment Troubleshooting Evaluate Dem/Val Results Track Test Sections Through 2-5 Launches SLC And Through Contract Period Of Performance For ICBM Sites Baseline Survey Service Environment Exposure Profile/Mapping Data Identify Most Corrosion/Erosion Prone Locations Existing Depainting, Preparation, Recoating Processes Coating Removal & Replacement Environmental Constraints, Concerns ICBM Site - User Needs And Constraints Identify Types Of On-Site Contractor/Gov Support And Support Equipment Available Available Life Cycle Cost Data On Refurbishing Launchers Service Environment Challenges SLS – Space Launch ICBM Structures Both Coastal and NW Arid Coastal Environment Vandenberg Test Missiles Combustion By-products •Combustion By-products Launch Temperatures •Launch Temperatures Coating Erosion Application Temperatures Application Temperatures - Humidity Physical Damage Environmental Regulation Water Intrusion Fuel/Coating Compatibility Environmental Regulation EMP Hardening Service Environment Exposure Mapping Table 1: SLC and ICBM Environmental Zones Environment Description Zone A Surfaces located in a marine environment that receive rocket engine exhaust impingement. Surfaces located in a marine environment that receive elevated temperatures above 65 degrees Zone B Celsius (above 150 degrees Fahrenheit) and acid deposition from solid rocket booster exhaust with no exhaust impingement. Surfaces, other than those located in Zones A or B, that receive acid deposition from solid rocket Zone C booster exhaust products. Surfaces not located in the launch environment but located in a neutral pH corrosive marine Zone D environment within 1 mile of ocean and less than 120m Elevation. Surfaces that tend to accumulate other types of chemical contamination (e.g., cooling towers, Zone E diesel exhaust stacks, diesel spills, brine chiller leaks, etc.). Zone F Surfaces located under insulation. Zone G Surfaces located indoors that are not in an air conditioned environment. Exterior Surfaces located in Arid Northwest Climate that receive cold winter temperatures below Zone H -20˚ C. Surfaces located in a continuous indoor air-conditioned environment below ground level and Zone I possibly below the water table. Zone J Surfaces located in a continuous indoor air-conditioned environment. Service Environment Exposure Mapping Table 2: Environmental Zones by Installation Zone Zone Zone Zone Zone Zone Zone Zone Zone Zone A B C D E F G H I J FE Warren X X X X X X Maintenance Industrial Coating Malmstrom X X X X X X Minot X X X X X X Industrial Launch Vandenberg Seacoast Heavy X X X X X X X X X ICBM Vandenberg X X X X X X X X SLC Cape Canaveral X X X X X X X X SLC Identify Most Corrosion/Erosion Prone Locations Coating Removal & Replacement Environmental Constraints, Concerns Lead Based Paint: 29 CFR 1926.62 “Lead”. Abrasive Blasting: California Approved List – PM10 Concerns Coatings from Code of Federal Regulations: 40 CFR 59.401 High Temp Coating (Max VOC = 650g/l) Industrial Maintenance Coatings (Max VOC = 450g/l) Rust Preventative Coatings (Max VOC = 400g/l) SBAPCD (Santa Barbara Air Pollution Control District) Rule 323 – (Local Vandenberg Restriction) High Temp Coating (Max VOC = 420g/l) Industrial Maintenance (Currently Max VOC = 340g/l; 250g/l effective 1/1/04; 100g/l effective in 2006) Rust Preventative Coatings (Max VOC = 400 g/l) Aerospace Coatings (Max VOC Topcoat = 420 g/l) Rule 337 (Max VOC Wing = 750 g/l) (Max VOC Primer = 350 g/l) (Max VOC Stripper = 400g/l) Depainting, Preparation, Recoating Processes Typical Inherent Capabilities of Field Units ICBM SLC Shop Corrosion Prevention Tools Abrasive Blast Booth Plastic Media Blast Outdoor area Paint Booth Minimum 10’ x 15, Heated None HVLP: Paint Spray Guns HVLP: Paint Conventional: Inorganic Zinc Portable Corrosion Prevention Tools Abrasive Blaster Small Portable Unit: 1 Bag Large Units: 6 Bag – 8 Ton Capacity Needle guns, Grinders, Descalers, Needle guns, Grinders, Descalers, Power Tools Sanders Sanders HEPA Vacuum 3 or More 3 or More for Hand Tools Pressure Washer None 2500 - 4000 PSI, Some Boss Units Metal Wire Arc 50% of Field Units Several Per Field Unit Spray Paints and Corrosion Preventatives Used Approved Material List and Local Paint Acquisition Military Spec and Local Purchase Purchase Baseline Coating Systems Maintenance Prep Primer Intermediate Topcoat Commercial Commercial Commercial Vandenberg SP 3 - SP 11 Aluminum Epoxy Epoxy Mastic Polyurethane M a Vandenberg SP 3 - SP 11 Inorganic Zn None None SLC 3 WB i n t SP6 Commercial Cape Brush Blast or e Canaveral Power tool Zn Rich Epoxy None None n Complexes SP 3 - SP 11 (Solvent Based) a n ICBM c SP 3 - SP 11 MIL PRF 53022 None TT-E-489 Interior e ICBM TT-E-489 or SP 3 - SP 11 MIL PRF 53022 None Exterior MIL PRF 85285 Baseline Coating Systems Refurbishment Prep Primer Intermediate Topcoat Commercial Commercial Commercial SP 3 - SP 11 Aluminum R Epoxy Mastic Polyurethane Epoxy e Vandenberg f Power Wash with u None None None baking soda r b Power Wash with I None None None Vandenberg baking soda s SLC 3 h Inorganic Zn SP 3 - SP 11 None None m WB e n Cape Abrasive Blast to Inorganic Zn t Canaveral SP 10 None None (Solvent Based) Complexes Surface Preparation Alternatives Baseline Less than Baseline Power Tool Cleaning To Bare Hand Tool Cleaning Metal With Vacuum Attachment Power Tool Cleaning Power Tool Cleaning With Alternatives Vacuum Attachment Open Abrasive Blast Cleaning Power Tool Cleaning To Bare with Expendable or Recyclable Metal Abrasives Other Methods Considered Sponge Jetting Wet Abrasive Blast Cleaning Vacuum Abrasive Blast Cleaning Ultra High Pressure Water Jetting Chemical Stripping Ultra High Pressure Water Jetting Combinations: With Abrasive Injection • Chemical Removal Followed by Sodium Bicarbonate Blast Cleaning Abrasive Blast Carbon Dioxide Blast Cleaning • Vacuum Power Tool Followed by Abrasive Blast Combinations of Removal Methods High Pressure Water Jetting Laser Removal with Vacuum High Pressure Water Jetting with Attachment Abrasive Injection Surface Preparation Potential Alternative Equipment Surface Preparation Testing • Coating Strip Rate & Costs • Surface Cleaning Level • Waste Generation • Airborne Particulate Generation • Damage to Substrate • Tensile Pull ASTM D4541 • Mandrel Bend • Gravelometer • Surface Profile • Investment & Maintenance Cost • Ergonomics Steel Surface Preparation Alternatives Paint Removers & Lead Stabilizers Paint Removers Lead Stabilizers B&B 5095 Blastox Abrasive Additive for El Dorado PR 5044 Lead Stabilization Napier Remove All 210, 1010 Leadx Abrasive Additive for Lead Stabilization Napier SV 35A Dumond Peel Away 1 Steel Grit ABR Grip N Strip 800 ABR Citrus Paint remover •Not All removers tested for Aerospace paste Applications of TO 1-1-8, Weapons system specific application Pretox 7000 •Additional alternatives are being considered Cee Bee E-2002 Paint Remover Test • Coating Dwell Time • Hypergolic Compatibility • Surface Cleaning Level • Recoat ability • Waste Generation • Cross Hatch Adhesion • pH ASTM D 3359 • Damage to Substrate • Wet Tape Adhesion • FED-STD-141C • MIL PRF 25134 M6301.2 • Immersion Corrosion • Tensile Pull ASTM • Sandwich Corrosion D4541 • Hydrogen • Ergonomics Embrittlement Potential Alternatives (Coatings) HIGH SOLIDS SURFACE TOLERANT PRIMER COATINGS • High Solids Penetrating Epoxy Coatings Process Description • High Solids Epoxy Mastic Coatings Process Description MWAS COATINGS WATERBORNE INORGANIC ZINC WATERBORNE ORGANIC ZINC POLYUREA HIGH SOLIDS COATING • Aromatic 100% Solids Polyurea • Aliphatic 100% Solids Polyurea Computer Based Training Points of Contact Air Force Corrosion Prevention And Control Office – Mr. David Ellicks, (478) 926-3284, DSN Prefix 468 Email firstname.lastname@example.org Science Applications International Corp – Mr. John Bloyer (478) 918-2946 Email email@example.com Mr. Michael Surratt (478) 918-2902 Email firstname.lastname@example.org QUESTIONS?