1. Major Dan Bullock Chief, AF Corrosion Prevention and Control Office
Corrosion Prevention and Control Survey Of Air Combat Command (ACC) 9 Sep – 9 Oct 02
Major Dan Bullock Chief, AF Corrosion Prevention and Control Office
DISTRIBUTION A. Approved for public release; distribution unlimited.

2. Overview Introduction Programmatic findings Technical findings
Recommendations and conclusions 2

3. Focus AUTHORITY AFI 21-105, Aerospace Equipment Structural Maintenance
PURPOSE
Evaluate ACC’s corrosion program
Assess condition of aircraft & equipment w/respect to corrosion, and materials & processes
On-site technical assistance and information exchange
APPROACH
Evaluation using AF and command instructions & technical orders (T.O.s)
Emphasis on survey and not inspection
Environmental awareness 2

4. Itinerary 33 FW Eglin AFB F-15 552 ACW Tinker AFB E-3
355 WG Davis-Monthan AFB A-10, C-130
27 FW Cannon AFB F-16
9 RW Beale AFB U-2
2 BW Barksdale AFB B-52
347 RQS Moody AFB HH-60, C-130
Out Briefing HQ ACC/LG 2

5. Survey Areas Aircraft Maintenance Environmental Management
Plans & Scheduling
Quality Assurance
Training 5

6. PROGRAMMATIC FINDINGS1

7. Programmatic Findings
COMMAND-WIDE PROGRAM
Overall program good
Aircraft good
COMMAND-WIDE AREAS FOR IMPROVEMENT
Unauthorized spot cleaners
Loss of large walk-in operational plastic media blast (PMB) booths
GUIDANCE
ACC instruction in place – comprehensive
Recommended formal assignment of Wing Corrosion Manager position – now incorporated
Good Operating Instructions at bases 8

8. Programmatic Findings
QUALITY ASSURANCE
Good
Use of Aircraft Structural Maintenance (ASM) personnel for aircraft acceptance inspections
AIRCRAFT WASH SCHEDULING
Excellent program
ACCI reporting requirement resulting in good wash most locations
AEROSPACE GROUND EQUIPMENT (AGE)
Corrosion programs need improvement
Exception: Moody AFB – Good program 8

9. Programmatic Findings
TRAINING
ACC Guidance Unclear
Initial/Recurring Requirements
Computer-Based Training (Corrosion) not implemented
Local Programs
Excellent
HH-60 Corrosion Training (Moody AFB)
Wash Video (Tinker AFB) 8

10. TECHNICAL FINDINGS 1

11. Aircraft F-15, E-3, A-10, C-130, F-16, U-2, B-52, HH-60 Good Condition
U-2s and B-52s in excellent condition
Leading Edges
Excellent overall; well maintained, very little damage 19

12. Structural Maintenance/ Corrosion Control
MATERIALS
Good use of authorized paints/primers/Alodine
EQUIPMENT
PMB cabinets in use; many booths inoperative
Use of vacuum-assist sanders
PROCESSES
Doing touch-ups/repaints for entire unit
FACILITIES
Need temperature controlled paint storage 8

13. Aircraft Wash/Rinse WASH Facilities: Very good @ most locations
Scheduling: Good!
Cleaners/Materials
Excellent use of proper materials
New A/C wash pad in use
Inspections
Quality Assurance (QA) Involvement
RINSE
Eglin AFB is working on getting rinse capability 8

14. Aircraft Painting GENERAL CONDITION Excellent overall
Leading edges good overall
Exception: structural patches
RECOMMENDATIONS
Sempens, brush/roller
Especially for structural repair patches
AFCPCO working with various vendors for Touchup kits 10

15. Other Maintenance Activities
No Significant issues found in:
Avionics
Munitions
Communications/Electronics
Pneudraulics 15

16. Aerospace Ground Equipment
GENERAL CONDITION
Fair to poor
TOUCH-UP PROGRAM
Use of unauthorized materials
OTHER
FL-D1 Floodlights - poor prep by manufacturer
Self-generating Nitrogen Carts
Moody testing coatings on fiberglass cover
AGE Contracts
Need to specify materials IAW T.O. directives 11

17. Vehicles OVERALL PROGRAM Varies; T.O.s not specific enough
AFCPCO and Vehicle Dir. revising T.O.s
GENERAL CONDITION
Varies greatly
PAINT PROGRAM
Some aggressive in-house programs
MATERIALS
Vendor-supplied paint mixing stations 13

18. Hazardous Materials UNAUTHORIZED MATERIALS CLEANING COMPOUNDS
Many unauthorized cleaners in use; authorized alternatives are available, and in use in other shops
CORROSIVE SEALANTS
SEALANTS
Identify by Mil Spec. vs. cure time
SHELF LIFE
Must be monitored 8

19. On-site Technical Assistance
We provided National Stock Numbers (NSNs) for cleaners, Sempens
We provided information on solvent cleaning equipment/processes
We reviewed contracts for painting AGE 15

20. Summary EXCELLENT COMMAND INSTRUCTION
Command Functional Management Excellent
AIRCRAFT IN EXCELLENT CONDITION
However, most AGE needs attention
WING CORROSION MANAGER
Recommended adding requirement to command instruction
T.O. AUTHORIZED MATERIALS
Understand current T.O. requirements
T.O.s change rapidly
FULL FINAL REPORT AVAILABLE AT AFCPCO WEB SITE ( 21