Low Temperature Cure Powder

CoatingESTCP PROJECT WP-0614

Mr. Christopher W. GeibScience Applications International Corporation 23 May 2007

Integrity ~ Service ~ Excellence

One Materiel CommandAir Force Materiel Command

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Overview

• Background• Project Concept

– Past– Present and Future

• Near-Term– Joint Test Protocol– Field Service Evaluations

• LTCPC Participants• JTP Progress

– JTP Test Results• FSE Progress• Expected Project Outcome• Schedule

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Background

• Temperature-sensitive Al & Mg is used throughout DoD for high durability & low weight

• Al and Mg can’t withstand the high-T cure ~350F of current powder coatings

• Results in continued reliance on high VOC solvent-based coatings

• SERDP Project PP-1268 developed VOC & HAP free, low temp cure coating for low-T alloys

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Background (cont.)

Traditional Primers & Topcoats

Waterborne Primers & Topcoats

Traditional Powder Coatings

Low-Temperature Cure Powder Coating

Compatible Substrates

Steel, Aluminum, Magnesium, Composites

Steel, Aluminum, Magnesium, Composites

Steel Steel, Aluminum, Magnesium

Advantages

Solvent flash-off leaves a uniform coating free of blemishes

VOC and HAP content are significantly reduced relative to traditional primers and topcoats

Single application coating; No VOC or HAP production; fast cure

Single application coating; No VOC’s or HAP’s; fast low temp cure ~30min@250F; enhanced corrosion inhibitors; improved transfer efficiency; primer application eliminated

Disadvantages

Environmental burden of high VOC and HAP production and release

Longer cure times than traditional primers and topcoats; still has VOC and HAP

High temp cure ~350F; Al and Mg substrates compromised; Can’t be applied at field level due to high curing temperature requirement

Currently, only proposed for depot production environments

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Background (cont.)Current Process

Proposed Process

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Project Concept

Past:• Original SERDP-funded

project explored low temperature cure chemistries

• Crosslink Powder Coatings Inc. iteratively reformulated LTCPC for testing

• Performance testing based on requirements of applicable MIL-PRFs

• Resulted in exterior-use, corrosion-protection powder coating that cures at 120°C within 30 minutes

Present & Future:• Partnership with Navy as part

of ESTCP-funded effort• Development of JTP

providing stakeholders additional performance data

• FSE to validate LTCPC within the operational environments

• Quantification of expected environmental savings

• Technology transition to Air Force and Navy depot production environment

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Near Term

For remainder of FY07:• Complete Joint Test Plan requirements• Generation of Joint Test Report• Initiation of USAF & USN FSEs

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Near Term – Joint Test Protocol

JTP:• Six substrates

(4 Al, 1 Mg, 1 Steel)• Eight performance

tests• HAFB Powder Coat

Facility (Oct 2006)• Initiated coupon

testing (Dec 2006)

Additional testing:• NASA special

interest items

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Near Term – Field Service Evaluation

• Ten performance tests for field-coated coupons

• Various Air Force & Navy components

• Qualitative field inspection methods

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LTCPC Participants

Validation Phase:• S&EL, Hill AFB, UT• NAVAIR Pax River, MD• CTC, Johnstown, PA• NASA, Kennedy Space

Center, FL

Evaluation Phase:• OO-ALC, Hill AFB, UT• OC-ALC, Tinker AFB,

OK• WR-ALC, Robins AFB,

GA• FRC NW, Whidbey

Island, WA• FRC SW, North Island,

CA

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JTP Progress• Results for

– Coating appearance– SO2 corrosion resistance– Filiform corrosion resistance– Cross cut adhesion– Impact flexibility– Strippability

• LTCPC passed all testing for each substrate considered

• No deficiencies or anomalies noted

• Salt fog and cyclic corrosion resistance testing ECD: June 07

JTP Substrate Matrix

2024-T0 Aluminum0.020” thick2024-T3 Aluminum0.032” thick6061-T6 Aluminum0.032” thick2024-T3 Clad Aluminum0.032” thickAZ31B Magnesium0.063” thick4130 Steel0.032” thick

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JTP Test Results

LTCPC AppearanceSubstrate Outcome

6061-T6 PassedMg Passed

Steel Passed

Control: PENDINGLTCPC: PENDING

Steel

Control: PassedLTCPC: Passed

6061-T6

Control: Passed

Control: Passed

LTCPC: PassedMg

* After 2000 hours

LTCPC: Passed2024-T3

OutcomeSubstrate

Salt Fog Corrosion Resistance*

EXAMPLE

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JTP Test Results (cont.)SO2 Corrosion ResistanceSubstrate Outcome

LTCPC: MARGINAL2024-T3

Control: PASSEDLTCPC: FAIL

6061-T6Control: FAILLTCPC: PENDING

SteelControl: PENDING

ControlLTCPC:

Steel

Control:

* After 500 hours

LTCPC:2024-T3 Clad

OutcomeSubstrateCyclic Corrosion Resistance*

RESULTS

PENDING

EXAMPLE

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JTP Test Results (cont.)

Filiform Corrosion ResistanceSubstrate Outcome

LTCPC: PASSED2024-T3 Clad Control: FAILED

LTCPC: PASSEDControl: PASSED

Control: PASSEDLTCPC: PASSED

Mg

Control: PASSEDSteel

LTCPC: PASSED6061-T6

OutcomeSubstrateCross Cut Adhesion

EXAMPLE

EXAMPLE

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JTP Test Results (cont.)

StrippabilitySubstrate Outcome

LTCPC:2024-T3

Control:LTCPC:

6061-T6Control:LTCPC:2024-T3

Clad Control:

Control:LTCPC:

LTCPC:Mg

SteelControl:

Control: PassedLTCPC: Passed

2024-T0

OutcomeSubstrateImpact Flexibility

EXAMPLE

RESULTS

PENDING

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FSE Progress• Identified AF and Navy components

– F-15 & F-16 Gear boxes– C-130 Landing gear doors– TF-33 Engine stators– Munitions skids– Aircraft tow bars– MJ-1 bomb lift trucks

• Slated for July 2007 start• Inspection intervals

– Non SOF: 100 flight hours– GSE: 6 months

• Exposure to demanding carrier environment for Navy components– Naturally corrosive– Stringent coating requirements

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Expected Project Outcome

• Full performance validation of LTCPC• Quantifiable environmental savings• Modification of applicable specs and

TOs• Transition to DoD depot-level facilities

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Schedule

• Demonstration Plan – July 2007• Joint Test Report – July 2007• Completion of FSE – Feb 2009• Cost & Performance Report – Dec 2009• Final Report – Dec 2009

Project Schedule

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Summary

• Validation Phase completion imminent• Evaluation Phase underway• Significant environmental impact• Focused attention on transition to field

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References

• Bloker, TSgt B. (2004) Air Force Link - Photos. Retrieved August 14, 2006, from http://www.af.mil/shared/media/photodb/photos/041110-F-2295B-083.jpg

• Kurle, Maj D. (2006) Air Force Link – Photos. Retrieved January 12, 2007, from http://www.af.mil/shared/media/photodb/photos/061104-F-3849K-201.jpg

• Nelsen II, J. T. (2003). US Maps Clip Art. Retrieved January 11, 2007, from National War College Military Image Collection Web site: http://www.ndu.edu/nwc/nwcCLIPARt/MAPS-FLAGS/US_Maps/us-maps.html

• Whidbey Island Support Equipment 900 Division Web Site.(n.d.) Retrieved August 16, 2006, from http://aimdwi.ahf.nmci.navy.mil/IMAGES/P1009064.JPG

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Questions?