haphmeatattom of Low VOC Surface Coathtgg

'Ibe hciTity wide coavmskm to hw VOC (Vohmle Organic Compound) asmspece primem and sspcoam for SS% of the coatings usage st tbc ~ Dhdsha was compleuxl oa July l. 1993. Tbe tmvhoamtmtal bsos6t wss a nuuar ooc, reducing pkmt wide VOC cmissions for surhce cosung pcations by S0%.

Beginning in Augmu 1991, thh pmgnun was established in response to dm Fu. Smm DER (spsrummt of Euvimnounud Rssmuces) requhsmeus to reduce smog fmming VOC emissionr fmm the six minor paint feei&ca on site. Tbe implrmtnuuion phm, devehped by SHEA (Safety Health sad Eevimnmeotsl ABshs), Opmadoas Tcchodogy, and Materials snd Pmcess Engineer, wss divided into throe phase%

Phase I involved the ~ implcmenmdon of low VOC w lsrbssed epoxy primem snd high solids topcotus for use on miTmuy snd commcrdd hmdware dmt cootiibomd so sa estimated usage of 14, 000 gagons/year. This npresented 70% of dte lolsl usage fsciTity wide. Extenive quaUBcmhas testing bad bess conducted by the ~ Diviskm ssd Boeing ~ T~ m Rcaum, Wm, to appmve dtese new castings befme pmducdoa use. As a melt, Bve compliant costing ftumuhdoas were sppmvsd for lbs Phase I implementation which began in January, 1992. Though these efforts Bbcghy wide VOC missioas worn reduced by 35%.

Phase II mqoind the mplaccmcnt of sg lacquer mpcoats used for cxteihr applicatioas oa miliuuy sBcoptem with a high solids chemical agent rsmtsnt (CARC) poiytusthme coethg det passed HeBcopters Divisioa qosliiicauoas lasting. Thc imphmsntstion of these coatings, however, foaowed Phase I due to factory impact. Sigaigcant fsciTitics modifications were requhed to implement these coatings imo pmducdon to canus wmhur safety duriag ~ Aho their 'ncorponmoo into tbe factory bad to be cmefidly managed by pmductioa planning snd conuol bccsosc they changed aircraft con6gmadoa (ie. farm, Br, or fuactkm). Consequently, ag ~ deudls snd assemblies painted with dus new costing hsd to be identiTied for instsBstioo oa specific hclicopuxx. This rcqshed mach discussioa with

cusumas m aocept the chmgn aad poht of ~ as wcB ss ~ msapower to ~ tleir implemeamdoa snd coatnd ahaaa ~. Pham B impscud IS% of tbe uual (20JXO gsgoas/year) coadags usage, android VOC ~ by an sditkmal 15%. Tbh effon wss cmnpletcd ou July I, 1993.

Pbsm III is ongoing snd involves tbe qasiBcstion and implcmmmu'oa of ~ for the nmuuniag coadngs, mahly special performance coatings aad adhesive prhners. These mslsrish compmmiss tbe ramsinhg 15% of the smhce coathgs usage at HelicopuxL Tbdr hw VOC subsdtutm wgl be tbe mots difBcult to qualify dae to thc hck of curnmdy avaBable alternadvca Tbe Boriag Company, however, bas baca ooducthg an htsosive effon m find suhable mphcemmus. An dsbonuc inungvisiond aebaQqp exchange netwmk bas baca eneblished to ~ infonnatioa and mpmt pmgram statuL Desphs the scheme dilBculty in Bmgag adcquam mphcsmcnts for nuns of these coat'mgs, ~ Diviskm mndns spurn'stic oncmning the ssccess of dds effort snd is actively ssehng sltmnstivsL

1bc ~ Division of the Boeiag Dsfeosc snd Space Omup msaufscuass Tsadcm Rotor Hegcopuxs for both mihuay aad ~ applhstkms, and nut)or wing ssschiss for BCAO (Boeiag Commcmisl Ahphme Gnmp) lu Seauh, Wss

' igliui. Ia adtgdoa, this Division is nlgsged

ia two mtttor dsvelopmcat progrsms fm the miTimry to msauhcuue the RAH M mconnaissance snack elicopux' sad dte V-22 Tilt Rotor Ahcndl 1bsse air vehides snd tbc aforememicosd pmductiaa cicopuss ead commemht hudwam perfmm special and mdmr unique fimcdoas in mrvicc wbge being exposed m a variisy of esvimsmenud or ouumh

' BucaccL 1be various peiot systems m "Surface

Coatings" med lo pnutet these prehcts Bom harsh cavmmments must meet spedBc perfonnance equkemeats m hub company aul custsmsr sptcigcstioos. Fsilme m mast dtese cduria jopsrdixm busmess base, positioa with

customers aad h some cams tbe lives of cmw members snd passengers For this reason, particularly the lnu one, any

Preteetes et tbe Attterbcte Hexceyter Seciety I let Atettttr Pereec Pert Wertl. rx. Hey S-I I. IN5. Ceyyrtrbt 0 I NS by tbe

eteericee Hdiicepter Stciety. Iec. AR rlrbte reeerted. ltw tec

1697

mqior change to tbe design of ahciafi aad associated barrhvsre, namely paint, mvrdves extensive tesung snd

Mowed by a myriad of mvisioos to ~ drawings, msteriri aod process specificstioas. snd

msnufitcturing plans prior to pmductkm imphzsumtatknz

Once the new coatiags am im~ manufactaring must,

in many cases. Bo duoagh an exunmely arduous lesraing

pmcess m opdmize dm apphcstion of these uuerials while

isrict cus oulcf IopUNDlMB.

Qsan Air Act egnhu'ons fiom the PederaL Shun, and Local level limit bszsrdoos air missions fmm smfsce cosungs

opemtions. Ccnain solvents ~ in these paints

evaporate into tbc ~ during application, and

pbotocbemically react in tbe preseace of suolight causing

smog. One of the major componems of smog, ozoac, is hazardous to both humans and plant Bfe. Tbc EPA, thmugh

the Clean Air Act, reydsm geese szsrdoas emissions by establishing barn&no connois to lhnit dte smmmt of smog

formers present in the aunosphere. 'Ibe State mgtdators may hl!Nunc cases, hnposc cvmi oleic stringcat reqililcnelts dzm

the EPA, if they are iu an ann of ozone non-stis' meat.

Such mquhements drive many diffenmt industries, including

semspsre, to implement coauols an their uufacc cosdngs endssioaa In tznue cases, dds means subsdwiaa widt a lower VOC material that meets a regulatory threshold. Or in

others, it would reqtme the instsation of stack contmls ia dm paint boodts to Blmi ~ air fiom uristing high

VOC coatings. Tbe lauer option, however, is merely a short

tenn solution with high non-rccaning and recmring cossz The ccospsre indmmy, as with other industriru mgulsted for surface coatiag pmcesses, mrna make imporumt businem

decisions to reduce eavironmeund risk while minimizing cost of change. Available options to reduce dds ridr (ie. end of stack contml technology va material subsdtution) wme

evaluated by Hclicoptem Division management prim to pmdacdoa implemeauuion. A clear undenasnding of dm

costs of dmse opdons coaphri whh a loag inay, vision of tbe

reydatory cfimste wss needed m make tbe righ choice. The remit was to ~ low YOC alternatives and minimize

pogauon at the somce.

Tbc challenge to execnm a fnciTity wide conerskm of high

VOC coatings to rdteinsdve Iow VOC ~ in a short

time frame wss aa exuemcly diificult sad cxpcsive one. The obvious rnvimnmmusl beae6ts mu wonh noting again,

however, of eqosl m greater impmumce is thc sbiTity of a large company to sdtqu m ~ changes while smying

focused on their primary objectives.

Facgity wide ase of oomplisnt low VOC smfitce coatings

(c 3S lbfgal as ecreincrB.

QldCCkhg;

Rcphrccmcnt of ag non~pgaat surface cwuingz with

compliant coadags ht one year.

7bc plan to hlly coavcri tbe e&coptem Facility to drese new

coathlgs incllldcd Ihc fofiowing hcy clcmcatu

I. Industry Survey

II. Qualifications Testing

IIL Specificsdon Coverage

IV. Imp~ Study

V. Poducthm Imp~

L Indludry Survey

Mstciias Enghtcering aod Operations Technology

investismri the avaihbiTity of low VOC candhhun primers

sad topcmus that would satisfy aB Heiicoptcs Diviskm

perfounaacc requkemeats for miTiuuy and commercial

hebrew Qualificd PioductsLhas for pp&Bcrdde

specificadoas wsza mvbwcd m identify de avsBsbghy of low

VOC coatings. VOC compgnnt condo&a bsd ahesdy bees deeloped for and spproveri to many of these specifications.

As a uuult, the ~ nuuerials wme selected fm quaBBcadtms testing.

~ MIL P455&2 Type I, Qsss I Epoxy Primer

Vendor. Deft - to mplscc: Tl'-P-1757 Zinc Quomste

MIL-P-23377 Cl I Epoxy Primer

~ MIL-P-&55&2 Type I, Qass 2 Epoxy Primer

Veador. Courthsulds - to replsctz TT-P-1757 Zioc Cbimnste

MIL-P-23377 Cl I Epoxy Primer

1698

~ MIL-P-23377 Ches 2 Epoxy Primer Vcadar. Evmmnl - to rcyhcL' Tf-P-1757 Zinc Chramsm

ML-P-23377 CI I Epoxy Primer

~ MLC-22750B Epoxy Taycaat Vendor. Evennal - to raphael MLC-22750 Epoxy Tapcost

Narc: Revisioa E to spec. far high sagds epoxy

~ ML&46168 High Solids polyunsbsne Tapcaat (Chemical Agent Rerisuet)

Vendor. Defl - e reyhcm Tl'-I 20 Lacquer Taycoat

TT/12/CSS97 Lscqms Taycaat MH L46159 Lacquer Topcoat ML-L-19538 Lacquer Tapcoat

~ MLC-85285 High Solids Pnlymethme Tapcaat Vendor. Deft

Caurthsdds - to replace: ML&413286 Poiymmhsne Tapcast

Boeing Msterish Tccbnolagy (BMI) wss caductmg deir own evaluation at thh time to appove law VOC prhnms and mpcosn for ose aa commerrisl shmnfL Sehcssd camhhmn wme being tested Io reyhce the foflowiag high VOC

nnerisls used on commmcisl bmdwsre msnufactmed at egcoptnz Divisioa. lhne wme:

~ BMS 10-11 Type I, Grade A Epoxy Primer ~ BMS 10-11 Type 2, Gmde A EPoxy ToPcoat ~ BMS 1060 Type 2, Grade A Pnlymetbsae Tapcaat ~ BMS 10-86 Type I, Grade A Teflaa Fifled Coating ~ BMS 1046 Type 2, Grade A Teflaa Iqfled Cmuhg

Adbesha of Ihe prhnms m chmmme ~ caved ahmham is a Mopes requhcmeaL Howevm, thee speriflcmioas dbl nat abbess primer adbesiaa m ader substrstmmto a ctevetshe coming which bad "aged". Recogaizhg that dehys nese yossibh ia a poducthe eavhoamcnL a 1-2 month delay was iocmpmucd whee applying de campflsat prime m almuinum panel@ Pnht sdbeshn to mhnr suhmmmrepeseating actual He 'coptem parts wme caacaneNy hvesdoued.

Primer/ Vendor. ML-P-85582/Courthaulds MH P415582/Deft MIL-P-23377 Ci 2/Evenesl

Sbzttsten 4130 Steel - cadmium plated per BAC 5701 Cl I, TII with oae coat of wash primer, per MIL-P-8514

AZ31 Magnesimn - coated widt One Of the following.

L Conversian coated per BAC 5609 b. Light HAE Amxgsc c. Heavy HAE Anodize, per ML-M45202

Primer Appflcsthnc Two cmns of each high VOC poducdoa prhner and hw VOC csadidam primer wme apphed ta each subcaste (0. 001 - 0. 002 hch nasl dry thicknem).

Test Proccdmm 1. Wct Tape Test (FED-STD-141 Method 63012) 2. Scrape ~ Test (ASTM D2197-86)

IL Quallflcatlons Testing

lie six crhicsl papenies fm ecch low VOC csadhhue anted st Hcicapem Divishe were:

L Primer-to-Suheste Adhesion H. Tapcost -to-Primcr Adhesion IH Crack etectian IV. Huid Resist V. Reacrivsrioa VL Crevice ~

Resehn Wet tape adbesiaa for tbe three campliant primms ayplied to sfl lbmri suhannm wem ~ whh oae cxacydae- Mt's 44GN-7 per MH P-SSS&2 over canvmrion cmmri magnesium. Scrape values far tbe dues compgmu pmners wme ~ since they wme campunbh tu cantnd values. both ia average snd warst case data.

Candusiona/Ream mendstimzc ~'s primer, which cmeuncd smetimn cbmnnue, yielded ~ test resohs, wbmeas tbe Deft primer cmeiniag barium chmnsm did aot. Prmxnamcat of s Deft planer cantahhg stranthm hlonlste was advised ta cvalmne a second quslifled sumac of Mi F45582.

1699

it was ~ dua mail foll imptemenmdon of knv VOC pnmcm and topconts, them coald be an husrim pmiod dming which a mix of krw aad high VOC coatings woaM be sppged to ahcraB (eg. applying cmapbant topcoats over noa-

comptbtm prhned surhtoes). Saduibctory adbeshm in this

case woobl pennh depbuhm «f edsthqt stock of high VOC paints. For dds reason, combinauoas of existing noa- complisat coadngs whh compgam coatmgs were evatoaauL

Chmnuue conversion cosmd almniaum test panels were

painted with two coats (0. 00141. 002 mcb total dry thickness) of emh primer hated below:

I. TT-P1 757 sine cluomste primer (cannot) 2. MII P-23377 Class I epoxy primei (control) 3. Mll P-23377 Ctsm 2 low VOC epoxy prhnrr 4. MIL-P-85582 low VOC Deft" epoxy primer

5. MII F45582 low VOC "Courtbaulds" epoxy prim

Within four burns after primer application, the test panels were ~ Oae coat (0. 001 inch dry thkknem) of each topcoat listed below, was applied to emh sct of primed psaeta

1. TI'-L-20 high VOC lacquer toPcoat 2. MIL-L-19537 high VOC bxxgstr mPcom

3. MIL-L. 19538 high VOC lacquer toPcoat 4. Mii L46159 high VOC lacquer topcoat 5. MIL-C-22750D high VOC ePoxy toPcost 6. MILC-227508 hw VOC egoxy toPcoat 7. MIL-C46168 hiw VOC palymetbsne topcoat S. MILC45285 knv VOC polyietbsae topcoat 9. MII D-2%03 low VOC walkway coating

After opcoadng, the trm panels were cmed at mom tempenmne for a miaimmn of saves dayx

Test Pmcedme: 1. Wet Tape Test (FEDSTD-141 Method 6301)

Results: Adhesion of all tweed topcoats to primers was ceptsbte with onc excepthm — Mii I 19537 lacquer over CouNumM's MIL-P-85582 primer. CompsdMity of all other compliant primers snd topcoats ai conuol coatings was verifuxL

Conctusi~mendadonn MIL-I 19537 lacquer, tbc oaly eceptioa. was not a concern since it was not fmmotatsd fcr applicsdoa to an epoxy prbner

(it is specie for MB P-7962, a high VOC lacquer primer). Punbennme, MIL-I 19537 was scheduled m be phased out of ploducdon

Overhaul of "fttgbt cridcal" toter and drive system omapmieats tequhe

' specticn fcr cmobs which may have

dtelopai in service. NmHbuantcdve spectioa cbtndques me effusive Sar crack dmccdoa where tbe paiat is smpped to bam mimi snd for cenatu britde paints, wbme strippbtg is not iequhtxL Ptdnt stripping is dme caasamhe, dighxdL snd an eavinmmenml baxmd shies cbeudctd stripplng is mquhed in dds case. Tbeiefme, using a pahu system duu will crack as tbe metal mbsmue cracks was highly deshable for this quatigcadou. Various combinadons of tbe Mown paints were udgxak

1. MIL-P-23377 Class I epoxy primer (conuot) 2. MIL-P-23377 Clam 2 low VOC epoxy prima 3. MIL-P 85582 knr VOC "Deft epoxy pruner 4. Mii p-a5582 Iow VOC 'Counhaalds" epoxy primer 5. MIL4 -8514 bjgb VOC wssli Primer 6. MIL~750D high VOC ePoxy toPcoat 7. MIL4:-22750E low VOC epoxy topcom 8. MIA. "MI68 low VOC polymethane topcoat 9. MILZ45285 Iow VOC polyuredume topcoat

Substistes: 7075-T6 aluminum - chomsm conversion coated per MS

6. 16

4340 Steel - cadmium plated per BAC 5701 Class I Type II

ZE41-TS magnesium - light HAE anodmri per MIL-M 45202

Test Spccimenn Twenty trm specimens were macbbud fmm emb of tbe three

btm (2. 0 x 4. 0) inch "dogboaes" and prepared for pshuing. A (1. 0 x 4. 0) inch wide strip of paint or combinatioa of paints that represent pmlocdoa pans wrse appUcd an tbe ceamr leagth of oae side of dm dogbane. After a man teuqieimme sevco day mioimum cme, each specimen was noscbed at tbe edge of tbe tnn sectioa, oa oae side duougb tbe thickness near tbe ccnaugne of tbe length. By applying an ~ fatigue loaL a crack was hutuocd iato tbe costcd mea of each ~ Test Procedme: 1. Flaoesceat Peneeant nspectioa per BAC 5423 2. Dye Penchant Inspection per BAC 5423

1700

Grouping s& 59 crack est spacimcas cofiacdvdy (ae wss "consumed" fm sct ap in &cuing Fsdgae Machine), a mh of singh sad m lticosts of VOC compbsat anima~&sat primers snd epooats warn ~ Cmck pmpagadon tbmogb de paim(s) wss such that de NDI~ crack knyh wss yester dea de subsuass crack laoyh for most spacimem There wme nore hrgc dfiamscas wbkh rapnsaat hihoe m pm&agee a atua&arable crack in det perticubn paint sysem. 1le crack laayh pnxhced even duoogh four cone of two VOICE - complima topcoats, MIL- C-22750D Epoxy nod MBA:46168 polyntaduue (ABC)

WhM. ~l $$ t Mt for MIA'. 4S285 VOICE - compliant polyumdene and flu MLC-22750D norH»mpgotu epoxy topcoat over Defeat's ML-P-&55&2 compliaat prime. MBA':22750D topcoat wss ~ for crack etactire whaa applied to sfl ader prhenx

Non-dastmcdve uat crack dctacdoa tbmugh sfl primers sad topcoats wss acceptable whh two ccept'ons — (I) MBA:- 85285 Polymedeac topcoru and (2) tbe combinsthe of Deit's ML-P-&S582 Epoxy primer snd MIA:-22750D Epoxy epcost. App 'catioa of these paints should be restriced to pans in which crack datacdon through the paint is not s considarsnon.

MILqec fluid reiststx» nquiremcots. for thc dnec kw VOC primcrs, did not indude sfl nuuarhh which wodd contact painted ~ Division psnL A compeoMhy investigation of elicoptm spacific msterisis in conuet with dfifcrent paiats wss aadertskm m pmvide de misshg data, Two cess (0. 001O. 002 hch total dry dudoem) of each of the following primers ware applied to chmnuua conversioa coster test psoebc

1. TT-F1757 sine cbmmstc primer (contml) 2. MI P-23377 Qass I epoxy priaer (sound) 3. Mi P-23377 Qsss2kw VOC aPoxy Primer 4. Mi F45582 kw VOC "Defi" epoxy primer 5. MB F45582 hw VOC "Cotudumbk" epoxy priaer

AB panels cmed at nem tampcnmne for saran days (mh ).

Test Pmcadee: Each set of five painted almninum panels wcm immersed or costar with the foflowing msuxisls for seven days, alter which thc dfccts on de painted subsuatcs were evahuuad.

1. MIL-L-7808 h ricstiag oil

2. P-D 680 sdveat 3. Jet A hal with Prba (and-icmg sdr&dve) 4. ML-H-S606 bythmlic oil 5. 1, 1, 1 - Tdcblaocthue 6. Trichkmcthykte 7. MLO41322 yeas 8. ML-T43483 snriudsa eompouad 9. Syo-Tach gnese

Immened panda wee nsnovcd fiom tbc Ibdds sflar saves days snd bkmxl whh a dean ~. P-D- 680 solvent, whkb did oct deyndemry primer, was used mremme de applied yese fmm tba out peach. AB paaals wme vbmn&y

cxsmhad snd pmbad with a wooden negus depreaux for any oridaoce of prinxx dayadstiaa ME P-23377 Class I sad Ddl's MIL-P45S&2 primcm passed saves days aqesme to thc nine conuet uucsisls. lie other primers fldlad oaly l, l, l - trichhmedume snd trkbhutetbyhm huacrskrx Two kw VOC primers (CounhmM's MIL-P455&2 aad Eversasl's Mi P-23377 Class 2) hilure modes vsricd fiem s&gbt bflserhg or paebag to mvembflstariag.

Cond Defi's MIL-P-&S582

primer

gama»uste acccptsbk to afl de msssrish tastnL A scves dsy immersion

in TCA or KX, which ML-P-23377 Clam 2 snd Ooutbsah's ML-p4SS&2 primcn did not pass, msy be

vs. band wiping with dese solventL A reduced dmc eqesme uut may have baca uxxe mesahtgfuL 'Ilesa too primcrs wme ~ acceptable whh a ~ note ~ TCA sad 1CE cleamng and cxposme (eg. vapor eyesiog). Both of these advene however warn

beiag phased oat at this dme for cnvinemaaod coaccmL

In pnxloctioa, if s significant daley occurs between primer snd topcoat spp&cstkn . the "aged" primer must be rascdvsaxl to easme adhesion of de topcoat. Ceruun Helicaym finish codes slow an optional chemical teacdvathm of tbe primer in lieu of de ML-F-18624 nxpdred plocedNL This lascovstea pmccdum wss evaluated for the tnv VOC prhnar qaaflficsdon. If uasadshcuuy, sa shmmoe paoccdme would be nacesssy. Two casts (0. 001O. 002 inch maI dry bickness) of ea:b primer listed below, warn spphed to chromos coaverste costar shmdnmn est panebx

L MIL-P-23377 Class I epoxy primer (contml) 2. ML-P-23377 Chas 2 kw VOC epoxy primer 3. MIL-F45582 low VOC "Deft" epoxy primer 4. MIL. P-&S582 kw VOC "Coartbsuhk" epoxy primer

1701

l. One dey at mom empwwme 2. Two days at mom temperstme 3. Seven days at mom empenmuc 4. Accdcrated cwe: 20-30 minuua at man ampereaae

foBowcd by 6000 mhnma nt 12SF

Test Spccimca Pnqtwminw

AS cwed punch wwe vriycd with aceuxe to remove aay swhce amtnmhenta S~y. tbe panel swfeccs wwe wcacd with ML-T-19S88 solvent aud eSowed to dry. A thin

coat of the hhaticsl primer wss nppSed to each tcn psael withia four bours of mscdvation. All mcoetsd panels wwe cured at mom temyerstwe for seven days minhnum.

Test Pmcedwe: 1. Wet tape test(FED4TD-141 Method 63012).

Resultn All en panda passed nectivsdon tcsung. Thee was no evidence of sny primer adherin to de ahuprly pulled tape or say lihing of primer aSer wct mpe test.

Condusiona/Recommendsdorw The three compliant prhners evelmued can be ren:tinued, when rcquked, by the cunendy used ~

Smove dhecuoa wright enghs to oee aaother fsdng de spedmen. This wss beld mgetber by a boh, two wssbers and s nat. A polyethyhne shave over de bolt enswed electrhsl isohtica of each aet specimrn.

Ten Pmccdnnx I. AS134 G48-76 - "Ten Method fcr Piniag aad Ccnoskm Rcshuwce of Stnhlem Seel and Rchusd Alhys by the am of Feme Chloride Solatkm"

Resuhc Each primer d'scoiced but sdg meuned its integrity such that conoion of de 4130 steel subsmus did not occw. Howcvw, Cwutbauld's ML-P4SS82 primer showed nwnwous small bhwss over the enthe syedmen smfsce. ML-P-23377 Qsss 2 bsd s few snail bgstem located mu of de spedmen aet mea. No vinlde cwrosion wss musd when a nmnber of bhuws wrac au away to oberve de snhstnue smhce. Feme chhrhh soladca wns oot present in the "boBow" hihuw.

Cond All thee hw VOC yrimers ymvided aevke ccnoske

fcr tbe 4130 easel en spec'mens. However. based upon de test results. de prefened ~ of hw VOC primers ro yevent aevice conoshn is (I) DdYs MIL-F- 85582, (2) MIL-P-23377 Class 2 end (3) C urthsuld's MIL- P-SSS82.

In 1990, concerns abmu pwamal aevice cwmsion pmblems

of 4XXX~ shel wee rwelved Som a 30 day ~ tnu mcded evalasring sevwul cwuhgs. It wns demweumed that MIL-P-23377 Class I high VOC primer pnwided ccceptnbh aevice conoskm pnectioa Evelwuha of tbe three VOC - compgaat prhnws for aevice conoshn wwe also ~. l. Mii p-23377 Class I epoxy primer (conuol) 2. MII P-23377 Ches 2 hw VOC epoxy primer

3. MIL-P45582 hw VOC "Dcit" epoxy primer 4. MIL P45S82 hw VOC Cowtbsohh" epoxy prhner

Test 8pccimenn 4130 Steel - Four (025 x 2A) x 2' inch whh s ccotenri 5/16-inch diameter hole. wae csdmiwn Flail per BAC 5701 Class I Type II, snd yahwri with one coat of wash yrimcr per MILC4514. Subsequently. each specimen wns coated with

one of tbe prhnas Ihmri above. Each tnu specimen wes betwcea two Tefkm phtm (025 x 2. 0 x 2. 0) inch

each with (0. 040 x 0040) iach Smove full length oa the (2. 0 x 2. 0) inch face. lie two phew wae yosidoned with de

All qasliScwioas test dam hd m be cweSNy mvicwed by Material aad Pmcess Eagineeriag begun specigcstkms codd be revised m ~ the new uuerisla lie ympcrdes of greaten cweern wae (I) edhcsioa of de primers e various ~ (2) adhesion of topcosts m primrrs snd (3) acceptable crack detection thmugh de various paint systems using non4cseucdve inspecdon pmcedwex Based upon this

aheris snd de tnu qua scaunulated, tbc following conchuicns wae msdn

1. Tbe Dch ML-P4S582, 7)qe I, Ches I, No. 4443N-7, her VOC primer wss unmctgushh based uyoa pour primer sdbeioa to Dow 7 coated megaesimn nnd uassthfectory cack denedoa daough dds primer in combinstioa whh two paint topcostx

2. Connsuld's ML-F45582 Type I, Class 2, No. S13X408, low VOC primer was acceptsbh for use. This judgment couskhrrd blhuering of the yrimer, which sdII ymvided aevice camskm pmtectkm, snd incompatibility of the primer with TCE sad TCA solvents ss acceptable perfonnance Ihnitadonx

1702

3. Siace an sharmue comes of ML-P4SS82 wsa dss'rable. soma ddB 'dorud msdng was memtmeadeL Choices should

include Dah's ML-P4S582 Type I, Class 2, whh suoatium chomstc to nuucb tbs varsho from Counbsuhh.

4. ML-P-23377 Cbuu 2 (a high solids vesioa of Qsss I) hw VOC primer wss ~ for use. This costhg system however, was nxymed for wet ieedlaim of hneaes in Bsu of tba Mll P4S582 ~ primer wMch was stthtcd fmm thh opestioa to mhdmise cormsioa palatial in water

trspyad mess. Shop BBcatcs in spplymg tbe ML P-23377 Qsss 2 yrimar jasd6ed adidoaal invemgadoa ames dm

costmg pefmmaace was ccccytebh. Also, irs usc woold not have mquired aay Baish code m dmwiag revishrus ushas tbe Class wss pccifieL

S. MLC-227505 hw VOC Epoxy tcycost wss ~ for me based apoa pessiag aB yerfonnsace tests

6. MIA:46168 low VOC chemical agent resisamt coating (CARC) polyuredume topcom was ccaytebh for use. Tbh wm bmad uprm psssag sB performance rests. Cosaxner pmfeenca wss fm thh ceuhg over ML4:45285 because of its chemical agent esstenca ppertier.

7. MLC45285 hw VOC polyletbsae topcom h conditionsgy ~ for um. Tlris mpcoat wss coosideed unacceptable for use where crack etectiaa duough tbe paht was required, but ~ whee s toogh, waubcr~L hw VOC topcmu was nccdeL

8. BMS 10-11 Type 1, Grade E water nxhcibh epoxy yrbner wss appmvcd for pmhctioa use at ~ oa commecial hmhvme. This coating passed aB qualiTicsdoas uming canducud by BMT snd wss incoqxxated into tba specificsthn oa Much 11, 1991.

Oa December 20, 1991 the foBowing hw VOC - comyhent surface coatings wee sccaytM for production use at the

Division:

1. Mii P-23377 Class 2 epoxy primer 2. MIL-F45582 Type I, Class 2 epoxy primer (Counbeulds

edy) 3. MLC-227508 epoxy topcoat 4. MLC~ 168 chemical agent rcsiasnr polyretbene

topcoat 5. BMS 10-11 Type I, Grade E epoxy primer (Deh mdy)

Limited infmmatica wss gadmmd dming qusliiicadons mmag ~ tbe bebavhx of tham new nuasrhh dming

Msnuhctmhg ~ were ccaductrd at dm tbne lo dahmnhe de best ~ to successMy ayply these sssrisls ia a pmdactha mode. Tba sppBcstioa af these cmuings requhed a diffamat sppmach by tba oyararrx lo eiectively apply theat Im ~ parts. Ibe nuttor issaas ead conccms with respect to pmducdas pyBcetbm

~ Dry to Topcoat Time ~ Pct Ufe ~ MElt Mlxlag

Pmdacdoa fhw reydred a hager dry m mpceu dme for tba Mi P45582 Type I, Class 2 yrhnrx. 'Iba contmglag pmcem sycci5cadon, BAC 5807, speci6cd a 4 to 24 bom dry

to aaycmu dme whbout mscdvsdorL Msnufscuuing required

a 2 m 36 hour window due ao tba hck of a tbhd shiiL Eaginaering sst ap an ia boom test to verify if this pmduction demand couM be met without resctivsthg tbe prhner. Teuing nuults wee ~ sad tbc syaci6csdoa was revised to rc5ex dra new time Bema.

Purdadady critical with tba BMS 10-11 Type I, Grade B water raduciMc epoxy primer fmm DrdL Tbe pot life of this

sysum was Rur borne m men tampenuue compeed to eight home for tba Grade A high VOC versiorx At 90F with high rehdve bmnidhy (&$0%) tbc pct Bga wss ~y mdaced m about trna boar. This wss an ~le coodhioa in pmdactoa. Tbc solatioa wss to cbiB bmb the mixed paint md mmdxcd compoaeats at m above tbe minimum axnpcnmne of 50P speci6ed in the cantmBhg pmcms speci6csdoa pcr BAC S632. lbe ~ of a

frigsread stomgc box fcr tbe unmixed crxnyoaaars (including deioixad water), aad small ndiigerators for drs Bve gsgoa preasme yots canned a four hour pot hfe dming tba nunmer months with high bast ead humidity.

BMS 10-11 Type I, Grade E primer wm scnsldve to the mixing ymcebna Tbe foBowiag stays were critical to this

ploccac

1. 85x ag (anthe ldt) of coaqxmeats A sad B. Note Kits werc not m be hokea down.

1703

2. Stage nduce wsau in oae-tbhd amounts, mhing thomugMy after each nducdurx

3. Mainudn viscosity between lg - 22 sec. in aZsbn 2 cup.

On Jsnumy 22, 1992, tbe imphmentsdon ylsa wss nwiewed

by peesdeaws T~ with dm sflhctrd imctiond «gsnhsdoas lbc nut)«sgeada Items were:

~ Review bsckgioond sad pmgrsm status

~ idnldfy under issues

~ Basblish imylemcnueou team

~ Impbmcatstion Plan

2. MIL-P-SSS82 Type I, Ches 2 epoxy yrhner (CounbsuMs) 3. MILC-227StRI epoxy mycom 4. BMS 10-11 Type I, Gnde E cyoxy primer (Deft)

lbe MIL4:40168 bw VOC polyureduum topcom nyheeamt f«hcquers, an the other band, ctmld not be implemented by Ab Aua ibis psrtbuhr paint system changed Ae elicoptcm perfonnance requhemcsts or conflgmatioa dae min chemical agemresisumt popcrdes, snd ss s nsuh requhcd hah customer syymvsl sad elfecdvity cmeol m Ae hctory. Ms menu a ~ scbcdub shde gsr pmductiaa impbmcatmba. A sepmme schedule wss needed f«Aese comhgs that would reflect the time lines for cbsages to customer caescm snd ymducthm phasing iequhemmts to c«eol shcrsfl effcctivhy.

Oae teyrescntadve wss sebctcd flom each of the folbwing uncdoosl orgsnisstioas to easMsh an effecdve

impbmeatmhm tease

Total High VOC Surface Coadngs

Suhaiuaas Approved

Coeaiom Without Sohmtuas

113

llsr qualificsdons tesung wss comphsed on December 20, 1991. The imylementsthm date commiucd to was Augast 2, 1992. The foflowing coatiags ~ was idcndflnk

Opstions Tecboology Invmeuy Management Contracts Qmdhy Flight Tea Mihuuy Pmgrsm Olflce Oflbad Ovarhml Pmgnun Comm«nial Support Ssbty, Health tk Envimnmcaud

Msteibb Eagineering FsciWies Design Engineering Manufacturing Pmject Enghccdng hdustrial Engineer Msnufsctming ngineerhg Spans Program Paint Shops (Six) Pmducdon Planning A

No Sabstiueu Rcquhcd

Subsdtutm In Tna

bhtjes Impbmsatatios Imasn

Pmductioa Phmning changes were required for the following plognmltc

CH4d dt CH47 Helicoytem Subcontmcttus Spares Progrmn Overhaul Pmgnun

Weekly mcedngs wne scbnhded snd caordhutud by pistions Tecbnobgy. Meedng minutes were pblishcd

ideadfying Ae major issms, action items assigtuxL sad Ae msm member ~ for each sctioa along with Ae required completion dare. A master schedule compiTing Aem uncdoasl scdons wss devebped snd conduimlly updated for

tntm mview to provide a coonlinatcd impbmeauuioa. Many sccomptbbmcre were made by the team members ~ Ae course of these meetings whbb continued on s weekly basis for sixteen months.

lbe folbwhg hnv VOC epoxy primers snd topcosts that

comyrised 70% of Ae fltctThy usage worn to be impbmaucd by August 2, 1992:

i. MIL p-23377 Chss 2 epoxy prime

Although many unponnu macs wme ddressni durmg Ae implemeatstion phase, the corn pbdoa of tbc folbwing mitmtones wne critical to the success of this effete

1 704

~ Dlvhhd hlplemt¹mdon eifiut hto Phasm Pbam I - Epoxy ydmcm and mpcaus Phase H - Polyurethane toycosts Phase IH - Fstae implemeamdca

~ BMS 1040 Tyye 2, Gmde D Polymetbaae Topcaa ~ BMS 1046 Type I, Gmde D Tc6oa Pi6ed Coadag ~ BMS 1046 Type 2, Gmde D Tefhm ymed Cauhg

~ ~ imylenu¹tadca d¹cs fa Phase LRH

Phase I - Aag¹a2, 1992 Phase H - Augu¹? 1993

1. Quslifhations coa'mg wss coahctM at sander Boeiag hcghy dadng Pbase H hnylemcnmthoL

~ Released Ossa I Enghmering Change Pmposal NCPJ for polyatsbane topcaus

- Required for customer sutorhation and reconcgistion to tbe ccaoact yrhr to implemeatation

~ Established cutover point for polyaetbncs Abash 3439 - Delivery ia July, 1993

ogistics of ccaversion based upon exhsing hvt¹taieiifhwdme m ensae 100% incapomdoo, BCP lead time, snd time frame fa customer ynxhcthm nms

~ Inidsud Pnxluct Revisioa Rccad 145-2195 - Coatrolhd ~ snd incatxustha of

yolymeUum paiat for existhg connects suudag with shcm6 3439

~ ~ hcaporsdtm of Ieworh phnohg hr pmvhosly psiaoxl lacqscr hmhnue ccedahd for final assembly past caovcr pohu

~ Ptda Adhesion ~ Toocb IJy ~ Iqnsl Ahaait Paint

MsteriaL 444HI-I I Water Rahcibh Epoxy Priner Vendor. DOR

Boehg Spcci6¹mac BMS 10-11 Typo I, Gmdc E

~ Esmblisbed a method to provide part number unusability tbnmgb hcqucr to polyaetbsae convershm witboa an

ginecring part number change

~ FccTitste of facuuy for polyaetluum application

- Appliauion of polyunbanes mqtrind ysint room isolation and bmsthsble Bash air

Pbsm I imp~ wss complesxl by Aug¹u 2, 1992 end insulted in tbe conversion of 70% of ~ Division sagtce cosdags usage. Gn July I, 1993 full amvendca of tbc odHtary ptdnoedurom wae incairoratcd ha the dtctory caaphtiag Pbam IL 'Ibis eifat shag with thc imldnnauatioa of tbe ~ casings spyroved by Bbff for commacial airuait subassemblies amtrihocd to sa additioaal 15% coavemhm based oa usage:

~ BMS 10-11 Type 2, Grade D EPoxY Toys™t

Backgmo¹L Altboagb all anodhnd alumham surfsao wae affected,

cmicaHy milhd sahces bad a Idgher haysmcy ofhilae. 'Hm msjorhy of the paint failaes occarmd daring assembly cyemt'oas mound rivet beads and ddll hdes bat wise not, however, limimd to these mess. Siignidcant dowatime and addidoasl labor costs noulted Bom tbe ssochtcd mwak,

if thc reworh mquhed removal of tbe hgcd part fnsn tbe assembly jig.

Sutycct Csos¹ Srohce amt¹uhsdca aod anodize process vsrinbhL Ibis nes paint sysmm ¹emed to be mae senshbe m Bnisbhe pmcem ariadoas dma tbe ohl solvcat bmcd hmnuhnoo aad this sosyhhm was coa6rmed by aber Boeing Divisims.

1706

Temng snd E~ A scmp ymt whh adhesion Mun» on chem-miged and a»- milled suihtcm was seat m Boeing ~ Technology Scr

evslustioa Smface aaalyals wss perguaud m hok for

posibh surface coatsminams and m dcmrmiae tbs mode of failms.

Analyshc ESCA (Ehctnm Spectmscopy for Chemical Auclysis) smhre analysis of both dm primer and dm suhmase side of d» hihue did not reveal aay ~ txmumdasnts.

Tmt Resultu Thee wss a sigaiBcmt smouat of slmninmn oxide oa tbe

primer shh which indicmed a cohesive Mme widua the

anodize layer.

Conriusioau The cohndve Mure widun the anodize layer ~ pmblems with the anodize pmoess. Sohtion ~ temperature, volmge, solution contamination (wig not

have reridus on ymts), iaahqem chsning sad deoxidiziag. or over sealing could all cmmibum m cohesive

anodhu failme. Ahbough no smhce conmminants wcm

found. the fact that d» pmblem accused mmo an ~y mgled smfaces suggested duu tbe milling conuilxued to tbe

yrrdd cut

Conective Acdoa: 1. Inauyomtcd a shot peen dsconuun' atioa sssp (5 mia

msx. ) fm sll cbemicagy miged parts prior to sandhi 2. Men@i the seal mquhement Bu 85% of suodiz»dSuimed

commmcial bsrdwme.

Rezuhs: Reject'om for paint sdheshm hss reduced by 80%.

Touch lip

Msterhdl 44QN-11 Water Rcducibh Epoxy Primer

Vendor. Deft Boeing Spec'ficstion: BMS 10-11 7)q» I, Grade E

cup, d» primer would foam aher brush ~ which was

unmcrquable. Ia tbe hue sprhg and nmuner mouths, dm

primar wss ahasdy nmhg up by dm dnm tbs opsrutru tstaratri to tbe wotk stash' It nmst be noted brse that ti»

mdacdoa ia yot hfe at shunted uxnpenmura wst dhcovenri dming d» msn~ trials ~ during

dm imphnmamdca smdy. Tbe easiest cribs, however, were

mu idemiBcd emly enough dus to the emybssh ylaced h couvmthg tbs nut)or paint sboya

Suspect Gmmr l. ~ the primer at elevate tsmpmauue oumgthms

Szddsally reduced d» pot life. 2. IBgh wmcr coatsat (150% ndacthm) of paint snd tyPe of

brushes anxL

Tesdng and Evslusdon: 1. Performed viscosity analysis at coauolled mom

tempurstme conditions to observe viscosity rise with

respect to thus 2. Coordinated with other Boeing Divisions on the foaming

pmbhm.

Rcmlcc l. Visccsuy doubhxl fern 19 to 36 sccomh hmreea 55 - 6

home st 72F using a Zebu ¹ 2 cup. 2. BMT mconimcnded ths following:

a) 75% rahcdon with water

b) use 4443N-57 Deft for a»eh-up oaly c) uy diifmeat bmsbes ru Q-dps d) uss csnridgc khz packaged by Counbsuhh

Conecdvc Actkxz l. Insudled refrigemuus in sealant cribs to maintain

pmdution scceptsbh pot life. 2. Changed pmcess speciBcation to reduce d» water content

by 50%.

Results: Achieved a workable pot life with rsrigsration sml minimized foaming to acceptable levels by reducing water

contest and impmving syplicstion techniqueL

Pmbhm: l. Extremely shat pot hfe shove SBF ambient.

2. Foemhg of yrimsr ahar bmsb sppliauioa.

Backgmuruk Production demands nqaire an hnmedhm sapply of toocbuy (small) ~ of mhed paint for Iocaliaed brush

zyygcsthm m suyyon ~ These qoantitiss would be

mhed m nhuux» for emergemrsqohementz aad dhyconri hom scahua cribs Bu wer sbopL Under normal conditions at d» recotnmcuded viscosity of (IS - 22) ssc. in a Zabn ¹ 2

Material: 0343N-236 Fht Gn»a Polymethane (Chemical Agent Reshumt Coathg)

Vendar. Deft Muerial Spscidcsdoa: MIIA:-46168 Type IV

1706 10

Bschgtoumh Bscemive gkss became evhhmt ader cme out of tbe polytumhmm extcrhr topcoat oa tbe CH47 Chinook

seoptssan Tide b a tejectsbb ccadhka shee dm cusuuucr teqahemcat is for a Bm pskt sysusa. Paint tbkhnem

tidings oa dm cmed Blm wee tbkhcr dma tequhed piculsrly in tbe paint overisp mess whom tbe gkss wss most evident The veador was coumctsd m pmvide technkst supp«L

Suspect Cause Shat pot life cstsdng poor Bow~ tesuldug in inctmsismm igm Ndaesa 'Ibk is congdtcsted by ibe escelhm "baog" cbamcteristks of dds psiat system alkwkg tbkh pskt Blms to sdbme to tbe ah«alt whhout mns « "~ As a msult, ~ ~ occms in tbe ddcher areas, psdculsriy whom tbe paint sppgcatica mcs overlap.

ZuhuSXEedg'

Implemcntsdcu of the fogowkg cauings for Pbam IIL

~ Dry Film Lubricant ~ Scale Inbgdt« ~ Adhesive Bomgng Primers ~ Ccmmendsl Bxterior Primae

Thc cstent of dus tdf«t, however, is condngsm upoa funue retptimtneats in tbe upcomkg NBSHAPiCTG (Nsthmsl Badsska Sumdmds for Hsssnkm Air polhasa~ ~ atdeelkes) whkb amy estsbgsh new duesholds that sane of dmse msnuials will meeL Odmr tff«ts to increase paint usnsfsr cfdckscy with HVLP (High Volume Low Pnusme) guns sad hnpmved spplksdcas ~ are aimed st reducing seas aad envimamental ric, whge

g bigb tpudhy stsndsnla

'Ibe Helical Divisica of the Boring Drfeum sud Spare Gmup Is ~ to bciag pmsctive oa cnvinmmcaud

isstmn Tbe ocmpsay bss deuumsusted tbm cmnmttmsm by to cbsgeagm whh a mum of mgeacy sad by

iavesdng dm msomctu seeded m devekp sad 'mplemeat

tdfecdve sobaknn

1 707