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Keith Legg, [email protected], 847-680-9420
Aerospace and Defense Industry Challenges
Keith LeggRowan Technology Group
NASF Technical Advisory Committee NASF Meeting, Orlando, 2011
Keith Legg, [email protected]
NASF Aerospace and Defense Roadmap
NASF Aerospace and Defense Roadmaphttp://www.nasf.org/AM/Template.cfm?Section=NASF_Roadmap&Template=/MembersOnly.cfm&NavMenuID=1260&ContentID=8193&DirectListComboInd=D
Keith Legg, [email protected]
Drivers for change in Aerospace and Defense Industry
RoHS and REACHVery serious issue for N American OEMs
US DoD policyNew DoD policies and acquisition regulations
Customer demandIncreasing demand for clean systems to reduce liability risk and regulatory impact
Improved performance, reduced cost of ownership
In reality improved performance/lower life cycle cost is one of the strongest drivers for replacing older materials
Keith Legg, [email protected]
Aerospace and Defense Roadmap
2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 20223 2024 2025 2026 2027 2028
Meeting regulatory requirements
Fuel efficiency – next generation GTEs and diesel engines
Fuel efficiency – lighter materials
Cost of ownership – material cost and performance
Cost of ownership – overhaul and repair cost
Underlying issues – Testing, IT and databases, modeling, design
Goals: Routes:
Meeting ESOH regulatory requirements Compliance with REACH, RoHS, OSHA, DoD, customer requirements
Fuel efficiency – next GTEs and diesels Lighter materials, higher operating temperatures, emission and noise reductions
Fuel efficiency – lighter materials Improved manufacture and performance of composites, light alloys
Cost of ownership – materials performance Lower susceptibility to damage and corrosion
Cost of ownership – overhaul and repair Easier, cheaper, faster repair, reclamation
Underlying issues – Testing, IT and databases, modeling, design
Improve data, testing methods, and modeling of the underlying science of coating processes to improve prediction, reduce time and cost to reach implementation
Other issues Development of specialized coatings
Other issues
Keith Legg, [email protected]
Cr6+-free paint systemsCr6+-free Mg treatments (see Corrosion protection for Mg)
Cr6+-free metallic-ceramicsCr6+-free bond primers
Cd, Cr6+-free fasteners, connectorsCr6+-free Al anodizingHard and Thin Dense chrome alternatives
Cd Plating alternativesPb-free anti-fretting
Low VOC topcoats, sealants
Meeting ESOH regulatory requirements
2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 20223 2024 2025 2026 2027 2028
REACH
• Annex XIV additions
RoHS
•Aircraft?•Military electronics?
• REACH Cd restriction, Vehicles
• DoD Cr6+ memo
Meeting ESOH regulatory requirements
Customer ESOH restrictions
• Aircraft• Vehicles• Vessels
Cr6+-free conversion, sealing
Whisker reduction for Pb-free electronics
Goals: Routes:
Cr6+ elimination from materials Trivalent and non‐chrome conversion coatings, sealers, paint systems, etc.
Cr6+ process elimination Non‐Cr plating, anodizing
Cd elimination Cd plating alternative adoption
Pb elimination from anti‐fretting coaitngs Pb‐free alternatives
VOC reduction Low VOC topcoats, sealants, etc.
Beryllium reduction, mitigation Alternative materials (coated powders), isolation coatings
Whisker reduction from electronics Solder modifications, mitigation coatings and treatments
Beryllium reduction, mitigation
Keith Legg, [email protected]
Environment and regulation
The biggest issue for the aircraft industry is environment and health regulation
Most aerospace companies putting a lot of effort into this areaEliminating Cd plate and chromates
Chromate primer, chromate conversion, hard chrome plate, etc.Be and other materialsNi coatings are critical to aerospace (wear resistance, rebuild)
Non-Pb solder is a serious problem because the riskWhiskers, fatigue, no settled alternative
Speed of required changeChange often required in 5 yrs, but traditionally takes 20 yrs
Keith Legg, [email protected]
Drivers – REACH
Some of the same issues for US and EU OEMsUncertainty over what materials will be restricted or Annex XIV, and whenUncertainty, constantly growing list of SVHCsRegistration issues – aerospace and defense usesCost of developing and qualifying alternativesSpeed of change far faster than traditional timescale for developing, qualifying, adopting alternativesUndefined and unlimited downstream costs
N American companies working hard to meet REACH requirements
Difficulties and disagreements over understandingNot sure there is the same understanding in US and EULack of Defense Exemptions serious issue for EU manufacturers
Keith Legg, [email protected]
April 2009 DoD Memo on Cr6+
April 8 ‘09 USD-ATL issued memo to minimize Cr6+ use, unless no cost-effective alternatives with satisfactory performanceMilitary organizations directed to invest in R&D, including funding qualification testingApprove qualified alternativesDocument Cr6+ health risksRequires Program Executive Officer (flag officer) and Corrosion Control and Prevention Executive (CCPE) to certify if no acceptable alternative
Similar to Lockheed approachIntended to force adoption of Cr6+-free coatings and production methodsUSD-ATL issuing a new memo asking for reports on implementation actions
USD-ATL = Undersecretary of Defense –Acquisition, Technology and Logistics
Keith Legg, [email protected]
Proposed DFARs – new language in future defense contracts
“…the Contractor shall not provide any deliverables under this contract, or use materials in performance of this contract, that contain hexavalent chromium in a concentration greater than 0.1 percent by weight in any homogeneous material.”
Unless authorized at flag level, or used in legacy systems, “…no DoD contract may include a specification or standard that results in a deliverable containing hexavalent chromium or the use of hexavalent chromium in contract performance.”
Applies to all components, no matter where made. Suppliers see similar language in some contracts already; DFARs will make it universal.
DFAR = Defense Federal Acquisition RegulationContract language for all DoD purchases of equipment, supplies, components
Will this apply to conversion coatings?
Keith Legg, [email protected]
Impact of DoD Cr6+ memo
Largest impact will be on aircraft because they useChromated primersChromate conversion coatings/sealers for Al alloy skins and airframes, Cd and other corrosion coatings, etc.Chromic acid anodizingMg alloysVarious washes
Vehicle impact will primarily be onChromate washes for prepaintConversion of Cd and ZnChrome plating on hydraulic actuators, etc.
All systems (inc. ships) use chromate converted Cd on fasteners and electrical connectors, and chrome plating on actuators
Impact will depend strongly on whether or not conversion coatings are exempt
Keith Legg, [email protected]
Indirect effects of Cr6+-related regulation
PFOS
Cr6+ in water
• EHC• Process
requal with alternative
• Plating• Conversion• Anodizing• Painting• Mg finishing
Keith Legg, [email protected]
WHAT ARE AEROSPACE AND DEFENSE DOING ABOUT Cd AND Cr6+?
Keith Legg, [email protected]
HAZMAT alternatives –Hard chrome plating
HCAT (Hard Chrome Alternatives Team)
US/Canadian team of OEMs, DoD, suppliers validated HVOF for Landing Gear, Hydraulic Actuators, GTEs, Helicopter Components, Propeller HubsProcess development, data, rig and flight testing – all publicly availableHVOF WC-CoCr now standard for all new landing gear, inner cylinders, pins, many hydraulic rods
High Velocity Oxy-Fuel thermal spray
Keith Legg, [email protected]
Primary reason for success of HVOF is better performance –less wear and corrosion, less seal wear/leakage
Actuator coating is no good if it just wears out the seals
Keith Legg, [email protected]
Other hard chrome alternatives
HVOF cannot be used for most internalsPulse plated nanophase Co-P under validation testing
Very similar in performance to chrome
Other electroplatesNanophase Ni-WCo composites
Electroless Ni-P for lower wear applicationsPVD diamondlike coatings for internals
Aerospace evaluations, no qualifications
Keith Legg, [email protected]
HAZMAT alternatives –Chromate conversion
All finishing chemical suppliers have trivalent and non-Cr conversion coatings and sealers
NAVAIR developed Tri-Chrome Pretreat (TCP) now licensed widely and qualified for many uses
Adhesion promotersUS Air Force uses Prekote on many systemsBoeing uses AC130/131 (aka Boegel) to prevent rivet rash
None of these adequate for unpainted use
Keith Legg, [email protected]
Paint systems, primers
Non-Cr primers becoming quite widely usedUS and European vendors
Fully Cr-free paint systems not generally acceptedTypical approach is to use non-Cr primer with chromate conversion or non-Cr6+ pretreat with chromated primerF-35, AH-64 use chromate conversion with non-Cr primer
Minimizes Cr6+
Aim is to go to Cr6+-free finish if acceptable performanceDeft is testing a new Cr6+-free paint system (pretreat/primer/topcoat)ESTCP program now underway to evaluate non-chrome primers
Typical approach is to use first on low-risk areas (easily monitored areas such as OML) and apply to successively more critical and harder-to-monitor areas, ending with inaccessible internal airframe areas and fuel tanks when confident enoughCr-free finish Boeing 777 now being flown by KLM
Keith Legg, [email protected]
HAZMAT alternatives –Cd plating
Aerospace and defense are sole remaining large users of Cd plateAircraft high strength steel, fasteners, electrical connectors
Electroplated Al (AlumiPlate) on some F-35 landing gear components, and other aircraft
Commercially availableNon-aqueous bath – no H embrittlementIonic liquid AlZr in development by Dipsol to avoid toluene bath
MIL specs for MIL-DTL-38999 and other electrical connectors now permit Al, ZnNi, electroless Ni-PTFELHE Zn-14Ni validated and approved by USAF
Hill AFB for landing gearAqueous bathEssentially equivalent to Cd
Military vehicles adopting metal-filled dip-spin coatings for fasteners similar to automotive (Magni, Doerken, etc)Ultrahigh strength CRES landing gear steel developed and validated
Commercially available as Cartech S53 alloy
Keith Legg, [email protected]
Thermal Barrier Coatings
Erosion resistant blade coatings
FOD-resistant coatings
Barrier coatings for CMCs, CCCs
High Temperature oxidation barriers
Abradables
Nacelle coatings
Fuel efficiency – next generation GTEs
2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 20223 2024 2025 2026 2027 2028
Goals: Routes:
Thermal Barrier Coatings New formulations, nanophase materials
Erosion resistant blade coatings Multi‐layer coatings systems
FOD-resistant coatings Coatings, compressive layers
Environmental barriers for CMCs Highly stable high temperature coatings to prevent degradation from oxygen, water, etc
High Temperature oxidation barriers
Better oxygen diffusion barriers, including multi‐component oxides
Abradables Improved high temperature abradables, including microballoons
Nacelle coatings Various coating improvements for erosion, abrasion, FOD
Keith Legg, [email protected]
Fuel efficiency – lighter airframe materials
2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 20223 2024 2025 2026 2027 2028
Fuel efficiency – Lightweight materials
Composite fan blade erosion, FOD
Composite tooling
Corrosion protection for Mg
Adhesion to Ti
Composite galvanic corrosion and EMI protection
Goals: Routes:
Composite fan blade erosion, FOD
Multi‐layer coatings, metallic coatings
Composite galvanic corrosion and EMI protection
Protective coatings for airframe, metallic coatings for composite electrical components
Composite tooling Coatings for composite tooling to provide wear/abrasion resistance with low CTE
Corrosion protection for Mg Plasma electrolytic oxidation, non‐chromate conversion, cold spray
Adhesion to Ti Etching, surface profiling
Lighweight armor Armor for vehicles, aircraft, personnel
Keith Legg, [email protected]
Lightweight materials
C-fiber (and some glass fiber) composites increasingly used for aircraft and vehiclesAbrasion and corrosion: Protection required for exposed composite surfaces such as composite GTE compressor blades and helicopter rotor bladesGalvanic corrosion: Coatings and shim protection required to prevent galvanic corrosion between composite skins and aluminum substructuresMg gearbox corrosion is a perpetual problemIncreasing use of plating on plastics for electronic componentsCoatings being developed to increase modulus and wear resistance for composites and plastics
Keith Legg, [email protected]
Cost of ownership – airframe materials
2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 20223 2024 2025 2026 2027 2028
Cost of ownership – material cost and performanceGoals: Routes:
Reduced airframe and vehicle corrosion Better corrosion coatings and paints for hydraulics, fasteners, electrical systems; aircraft frame, skin, landing gear; vehicle frame, armor
Reduced wear Better wear coatings for functional components (landing gear, hydraulics, etc)
Reduced erosion, abrasion, FOD damage More resistant coatings on exposed areas, leading edges, landing gear, radomes
Water drop erosion Better radome coatings for high speed military aircraft
Helicopter blade erosion Coatings resistant to sand erosion
Reduced corrosion (see also ESOH: Chromate alternatives, Cd plating alternatives)
Reduced wear (see ESOH: Hard and thin dense Cr alternatives)
Reduced erosion, abrasion, FOD
Keith Legg, [email protected]
Cost of ownership – airframe materials
2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 20223 2024 2025 2026 2027 2028
Cost of ownership – overhaul and repair costGoals: Routes:
Rebuild automation Automation of the evaluation, tool path, rebuild approach for damaged blades and other components
Rebuild coatings for Mg Method for rebuilding damaged or corroded Mg alloy gearboxes, etc
Strippers GTE, including TiN, TiAlN More effective, less toxic stripping methods for engine coatings
Strippers blade passages Stripping methods for internal blade passages (liquid or gas based)
Depainting and repainting Cleaner, faster methods of stripping and repainting
Rebuild coatings for Mg
Strippers GTE
Strippers blade passages
Strippers paint
Rapid repainting
Keith Legg, [email protected]
Cost of ownership
We are always looking for better and cheaper ways of repairing worn, eroded and corroded componentsWe are always looking for paint systems with better long-term performance, slower degradation, better corrosion resistance without chromatesConstant challenge is to rebuild components to restore not just dimensional tolerance, but also strength
Having some success with high velocity, He-based cold spray
Keith Legg, [email protected]
Cost of ownership – airframe materials
2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 20223 2024 2025 2026 2027 2028
Underlying issues – Testing, IT and databases, modeling, design
Goals: Routes:
Process modeling, control, portability
Understand physical processes of coating, in order to improve portability and reliability of coating processes
Coating integration Integrate coatings with design tools
Build/rebuild automation Automation of the evaluation, tool path, rebuild approach for damaged components
Accelerated implementation Development of better understanding, development, test, business systems for rapid development, qualification and diffusion of coating technologies
Materials modeling and design Modeling physical deposition processes and using models in design of coatings
Prediction Prediction of galvanic and salt water corrosion performance,
Build/rebuild automation
Accelerated implementation
Process modeling, control and portability
Coating integration with design
Materials modeling, coating design
Prediction
Keith Legg, [email protected]
Cross-cutting issues
2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 20223 2024 2025 2026 2027 2028
Other issues
Ice-phobic coatings
Coatings for use with alternative fuels
High temperature non-skid coatings
Goals: Routes:
Ice-phobic coatings Coatings for flight surfaces, engine nose cones, etc to reject ice build‐up
Coatings for use with alternative fuels
Engine fuel system and hot section coatings that may be needed for using alternative fuels
High temperature non-skid coatings
Shipboard deck coatings able to withstand engine exhaust of new STOV/VTOL aircraft
Anti-foul hull coatings for reducing drag
Blast mitigation coatings for vehicles, buildings
Keith Legg, [email protected]
Need thermal barrier anti-skid needed
New VTOL/STOVL aircraft will overheat decks
Keith Legg, [email protected]
Faster, better, cheaper
Need to accelerate design, qual, implementationModeling, accelerated testingBetter tests – faster but more realistic, esp for corrosion
Galvanic corrosion constant issueComplexity of new designs, specialty coatings, new materials leading to galvanic corrosion seesNew computational approach has a lot of potential for avoiding costly galvanic corrosion design errors, integrates with standard CAD design software to show corrosion rate over entire assemblyNew Coatings Database (Granta/Rowan)
Keith Legg, [email protected]
Information sources – ASETSDefense
Keith Legg, [email protected]
Upcoming Workshops
Programs, briefings, summaries of previous workshops at www.asetsdefense.org, www.nasf.org
http://workshops.serdp-estcp.org/ad11
http://www.nasf.org/Content/NavigationMenu/NASFEventsPage/WashingtonForum/default.htm
http://www.nasf.org/Content/NavigationMenu/NASFEventsPage/SURFIN2011/default.htm