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Presented to:
Presented by:
NAVAIR Corrosion Program Overview and
Recent Initiatives
Air Force Corrosion Conference
Dane Hanson
06-June-2017
NAE CPT Future Readiness LeadDISTRIBUTION A. Approved for public release: distribution unlimited.
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2
NAE Corrosion Impacts
➢ The impacts of corrosion to the NAE are significant
▪ Accounts for over $3.6B annually = 27% of all aviation maintenance support cost
▪ Reduced operational availability and mission readiness of NAE aircraft
▪ Unpredictable maintenance budgets, scheduling & execution
▪ Reduced effectiveness of lifecycle logistics support systems
▪ Degraded A/C Service Life Management (SLM) programs
➢ Improving aircraft corrosion abatement efforts throughout the NAE is
essential to minimizing these impacts
Based on 2014 LMI Cost of Corrosion study
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3
Safety Mission Readiness
Total Ownership Cost (TOC) Service Life Management (SLM)
NAE Corrosion Prevention Team
➢ Chartered 2007: CNAP N42, NAVAIR, FRC, Platform FST/ISSC & Fleet
corrosion SME
➢ Prime Objective: Improve airframe material condition through systemic
corrosion abatement strategies to reduce corrosion impacts to:
➢ Strategy: Reduce NAE platform corrosion support cost & improve aviation
readiness through four Strategic Objectives:
Data: Improve corrosion maintenance
data reliability for decision makers
Policy: Improve corrosion policy,
communication & abatement strategies
Training: Build and sustain platform
centric, core material condition
maintenance capability
Engineering: Resource technologies to reduce
corrosion and related costs
4
Commander Naval Air Forces CPT Operational Logistics
(N422)
NAVAIR CPT Sustainment Logistics
(AIR 6.7)
NAE Board of Directors
Engineering, Maintenance & Supply Chain Management (EM&SCM CFT)
NAE CPT Organization
Future Readiness Corrosion Lead (AIR 4.3.4.6)
Current Readiness Corrosion Lead (AIR 6.7.2.1)
CNAF N422 (Plans and Policies)
5
FY17 NATEC C-MRT Distribution
FY-17 C-MRT End State
NATEC FLEET CETs: (46)
NATEC FLEET NETs : (20)
NATEC RESERVE CETs: (7)
Norfolk (1) (3) (1)
C-2/H-60/E-2/H-53/H-53(r)/
V-22(r)
Cherry Point (1) (2)
AV-8B/EA-6B/C-130
Stewart ANGB (1)
C-130McGuire AFB (1)
H-1/H-53/C-130
NAF Washington (1)
C-130
Quantico (1)
V-22Oceana (2) (6)
F-18
New River (1) (3)
H-1/H-53/V-22Beaufort (1) (2)
F-18
Jacksonville (1) (3)
P-3/P-8/H-60
Mayport (1) (1)
H-60
New Orleans (1)
C-130/F-18/H-1
Whidbey Island (2) (3)
P-3/P-8/EA-18G
Lemoore (2) (5)
F-18Pt Mugu (1)
E-2
Camp Pendleton (1) (2)
H-1/V-22
North Island (1) (4)
C-2/H-60
Yuma (1) (1)
AV-8B
Miramar (2) (3)
C-130/H-53/F-18/V-22
Fort Worth (1)
F-18/C-130
Kaneohe Bay (1) (2)
H-1/H-53/H-60/P-3
Atsugi (1)
H-60
Iwakuni (1) (3)
F-18/E-2/EA-18G/C-130
Okinawa (1) (1)
H-1/H-53/V-22
C-MRT Transition to NATEC➢ FY17 C-MRT End State in place MAR17
➢ Combined all C-MRT efforts under NATEC management.
➢ End of FY 17 Planned: ➢ Add 11 C-MRTs with additional focus OCONUS
➢ Japan (+6) and Hawaii (+2)
Current Readiness Team Priorities
• Policy: COMNAVAIRFORINST 4790.2C, “The Naval Aviation
Maintenance Program (NAMP)” (REVISION PUBLISHED IN 2017)
• Fleet: 01-1A-509, “Cleaning and Corrosion Control” General Series
Manual or platform-specific repair manual
• Data: Improved data quality by improving inspection processes and
ratings, data capture means, malfunction codes and pilot assessments
of hand-held device for entering data during inspections – Automated
Data Capture System
• Training: “Corrosion Control for Managers” course, Wing MCI and FAL
training, “A” School corrosion curriculum updates
• Communication: Corrosion Maintenance Readiness Team (C-MRT),
Corrosion Fleet Focus Team (CFFT), and platform FST/CPAT
involvement with fleet, depots, and OEMs
• Deficiencies: Focus Area Lists (FAL) & Root Cause Analysis (RCA) –
focused effort in FY16-17 to identify and resolve documented corrosion
degraders
6
Focus Area List Overview
FALs are a major part of the NAE’s corrosion mitigation strategy because they:
• Provide robust communication between RCM ISSCs/FST, Depots and O-level
• Promote innovation in tools, materials and techniques
• Focus & align TMS specific corrosion prevention, detection & treatment in the Fleet
• Provides business case/RCM criticality analysis for logisticians and maintainers to prioritize
resources on problematic corrosion prone areas
The Focus Area List (FAL) is an FST developed list of the top 20 percent of
platform corrosion degraders
The FAL is derived from all
Level 3 Corrosion Related
workload documented during
PMI events
• Chronic Corrosion Degraders
• Labor Hours• Material Costs• Large % of Total PMI Cost
Frequent
Occurrence
during major
PMI events
Consumes
largest
maintenance
resources
7
FAL Item RCA & Mitigation
FAL Item Root Cause Analysis & Mitigation using CPI Methodology
Perform Root Cause
Analysis
Brainstorm
mitigation strategies
Socialize, Refine &
Publish Action Plan
Create Action PlanSelect best
mitigation strategy
Select
FAL Item Discuss issues & agree on
key contributors
Categorize
Issue/Competency
Team
Participation
is paramount
TrainingTools,
MaterialsMaintenance
PlansECP Policy
8
NAE CPT Future
Readiness Team
9
National Future Readiness Team
10
Future Readiness Team Site Alignment
11
CORE FUNCTIONS/ PROCESSES
FULL LIFE-CYCLE MANAGEMENT
System Life Cycle Responsibilities
HEADQUARTERS / PEOs
WARFARE CENTERS / DEPOT/ INDUSTRIAL SITES (FLEET READINESS CENTERS)
OPERATIONS &
SUPPORT
PRODUCTION &
DEPLOYMENT
ENGINEERING AND
MANUFACTURING
DEVELOPMENT
TECHNOLOGY
DEVELOPMENT
FUTURE CAPABILITIES CURRENT READINESS
MATERIEL
SOLUTION
ANALYSIS
S&T, R&D, HARDWARE, SOFTWARE PRODUCTS, DESIGN
Conduct Efforts Focused On The Advancement Of Science, Technology, Research And
Development And Delivery Of Hardware/ Software Products
IN-SERVICE ENGINEERING & LOGISTICS SUPPORT
Analyze System Data, Determine / Implement Corrective
Actions To Sustain In-service Systems And To Ensure
Safety, Affordability, And Availability; Perform Engineering
Investigations, Engineering Change Proposals
ACQUISITION MANAGEMENTPerform Acquisition Management For The Development, Production,
And In-service Support Of Aircraft And Weapons Systems
COMMAND MANAGEMENT AND SUPPORT OPERATIONSDevelop/ Maintain Competency Policies, Procedures & Support Services.
Facilitate Effective Utilization Of Infrastructure, Security, Legal, Financial, Mgmt, Personnel & Info Resources
PRODUCTS
TACTICAL AIRCRAFT
UNMANNED AIRCRAFT & STRIKE WEAPONS
COMMON SYSTEMS/ MISSION SYSTEMS/ TRAINING/ ALRE
AIR ASW, ASSAULT & SPECIAL MISSION
REQ’Ts / RISKS
FROM FLEET/
OPNAV
TEST & EVALUATIONTest & Evaluate Aircraft, Weapons & Integrated Systems; Science & Technology For Test & Evaluation
REPAIR & MODIFICATION
Provide For The Repair And/ Or Modification Of
Aircraft, Engines, Systems & Components
Acquisition Management Support
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System Life Cycle Responsibilities
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14
Future Readiness Team Priorities
• Complement Existing Sustainment Efforts Identify resource constraints within the PMA and/or FST
Complement teams – e.g. CAT, CPAT, CPAB, CCWG – where team members already have a presence
• Improve Material Availability for Field Corrosion Control Identify sole source, long lead time, short shelf life hazardous materials
Evaluate mitigation to identify equivalent alternatives, improving procurement processes, or extending shelf lives
• Establish feedback loop between legacy aircraft and new acquisition (H-53E H-53K, E-2C E-2D)
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15
Future Readiness Team Priorities
• Implement Corrosion Control Design “Best Practice” and Modernize Based on CPT-Validated M&P
MIL-STD-1568, “Materials and Processes for Corrosion Prevention and Control in Aerospace Weapons Systems”
MIL-STD-7179, “Finishes, Coatings, and Sealants, for the Protection of Aerospace Weapons Systems”
SAE-AS-12500, “Corrosion Prevention and Deterioration Control in Electronic Components and Assemblies
NAVAIR EC-434-000-005, “Corrosion Prevention and Control for Navy & Marine Corps Aviation Systems”
• Assist RDT&E Transition Efforts
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Corrosion Specs and Standards
16
NAVAIR Corrosion Engineering Circular
• Content
– Volume 1: Acquisition
• Program CPC Guidance
• System Design CPC Contract Language
• CPC Trade Study Information
• Corrosion Verification and Validation
Criteria
• CPC Program Assessment
– Volume 2: Sustainment (in progress)
• CPC Lessons Learned
• Impact of Corrosion on NAE
– Appendix
• Corrosion Airworthiness Requirements
17
FA-18 FAL Mitigation Example
18
FA-18 FAL Mitigation Example
19
Other Cross-Platform
Priority Areas
20
Priority #1 – Aircraft Interiors
• SERDP WP-2747, “Mechanistic Study of Fungi Degradation of Organic Coatings
used in Aircraft Finish Systems”
• Problem Statement:
Aircraft are exposed to extreme environmental conditions – heat, humidity, salt,
operational fluids, etc.
Microbes in hot/humid environments feed off of organic materials – coatings,
CPCs, hydraulic fluids, etc.
Aircraft interiors receive limited-to-no exposure to UV-light to disable growth of
microbes
Aircraft interiors are equipped with complex wiring, hydraulics, and avionics
systems that make cleaning and treatment difficult
• Approach:
Prepare standard and novel finish systems and expose to microbes
Identify which components retard microbe attachment and proliferation
Design new finishes incorporating low surface energy or biocidal additives to
finish aircraft to avoid costly and time-intensive remediation operations and
prevent exposure to microbe spores – breathing hazard
Task 1.1 – Lab Study
Task 1.2 – Mildew Box
1450 Black Pelican Box
Water Tight filled with Fluid
to increase Humidity.
Water reservoir in the bottom of the
box just below the perforated sheet
(Approx 3.5”)
Note: Box will have holes around
the perimeter to allow for spore entry and
circulation. Need to identify the minimum
sized holes which will allow free entry while
minimizing unwanted entry and moisture
loss.
Environmental Box to Study Mildew
Growth Patterns
EMERGING BEST PRACTICES TO BE TRANSITIONED INTO
THE MIL-STD-7179 AND/OR 01-1A-509-2
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Priority # 2 – Electrical Wiring
Interconnect Systems (EWIS)
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• Problem Statement:
Aircraft are exposed to extreme environmental conditions – heat,
humidity, salt, operational fluids, etc.
EWIS in SWaMP (Severe Weather and Moisture Prone) areas exhibit
high rates of degradation
Even with current authorized materials, EWIS still corrode over time
A comprehensive study of potential EWIS finishing options has never
been completed to characterize cost / time versus benefits
• Approach:
Prepare standard and novel finish systems and expose to simulated
environmental conditions – ASTM B117, ASTM G85-A4, GMW 14872
Identify which finish options efficiently delay the initiation of corrosion and
inhibit performance degradation
Balance intensiveness of the process versus the benefit achieved – what
is achievable in the field with the time and materials available???
Task 2 – Lab Study
• Control versus One Commercial Product Applied to the Backshell
Exterior
Task 2 – Lab Study Results
EMERGING BEST PRACTICES TO BE TRANSITIONED INTO
THE SAE AS12500 AND/OR 01-1A-509-3 / 01-1A-505
Priority Area # 3 – Aircraft Storage
27
• Problem Statement:
Aircraft are exposed to extreme environmental conditions – heat,
Ultraviolet light, inclement weather, etc. – during operations and storage
Environmental factors contribute to degradation to non-metallic materials
that are used on aircraft and produce difficult working environments for
regular aircraft maintenance
Some operational units have Aircraft Protective Equipment (APE) to
reduce degradation rates and provide satisfactory working conditions
A cost-benefit analysis of the benefits of APE has not been performed to
justify their usage beyond current units
• Approach:
Evaluate the thermal- and UV-exposure of aircraft substrates on Summer
days at known prone locations – both exposed and covered by APE
Assemble database of non-metallic materials on aircraft and their thermal
stability / activation energy / susceptibility to UV
Track rates of degradation of aircraft materials through known databases
Task 3 – Field Study
EMERGING BEST PRACTICES TO BE TRANSITIONED INTO
THE NAVAIR EC-434-000-005
Hazmat Availability
Improvement (HAI)
Initiatives
29
• Problem Statement:
Hazmat are necessary for accomplishment of routine / scheduled
maintenance and un-scheduled repair
Hazmat availability is compromised due to SHORT material shelf life,
LONG lead time, SOLE source, MINIMUM purchase quantity, etc.
• Approach:
Determine the root cause of material non-availability by discussion with
stakeholders (e.g. Environmental Logistics, Purchasers, Users, Suppliers)
Brainstorm alternatives to circumvent or eliminate the major root causes
Modify conditions and evaluate performance of hazmat after exposure to
test conditions
HAI Initiatives Overview
• Extended shelf life of touch-up
applicators
• Non-Chromate 2-component aerosols
• TT-P-1757 modernization
• Epoxy primer re-activators
• Reduced VOC Non-Chromate primers
for Ground Support Equipment (GSE)
• MIL-T-81772 modernization
• Polysiloxane topcoats + Al-rich primers
HAI Initiatives Scope
Summary
32
• Corrosion is a significant cost, service life, and availability degrader
• The Naval Aviation Enterprise Corrosion Prevention Team is attacking corrosion in all phases of the weapon system life cycle
• Dane HansonNAE CPT Future Readiness Lead, Corrosion and Wear Branch
Improved corrosion design will have the greatest impact over asset life cycle