1. Paint & Coating Operations
Steve Allen
P60
29 March 2016
Paint & Coating Operations

2. Background Painting and de-painting is MDMCs biggest “choke point.”
The MDMC steam, blast, and painting operations and facilities are basically all manual and labor intensive which result in high labor costs for our customers. These work centers also represent the biggest production constraint within the two plants. Production lines can be delayed waiting on components and/or vehicles to be processed through these manual processes.
In order to increase throughput, the Coatings Branch work centers operate two shifts per day and both shifts employ overtime on each shift providing approximately 22 to 23 hours per day of production, 6 to 7 days a week. Even though some of the equipment has been renovated recently, MDMC still experiences too much down time due to equipment and facility failures.

3. Substrates/Paint Specifications
Zinc Rich
Wet Mils
Dry Mils
Primer
Topcoat
MIL-A-12560
Zinc Rich, A-A-59745
5.0 min
2.5 min
MIL-DTL-53030
1.5 minimum
CARC, MIL-DTL-53039, TY III(ext)
N/A
Powder, MIL-PRF-32348
CARC, MIL-PRF (int)
CARC, MIL-DTL (ext)
STEEL, A-36
6061 AL
MIL-STD-46100

4. Current Depainting Process
Almondite Garnet blast is currently the preferred method of de-painting
Blast booths (6) are multimedia
Using a pressure vessel for paint stripping of some components
Also use some steel shot and glass beads for small components
Blast grit is our largest waste stream
Vast majority of workload consists of heavy steel, armor and aluminum
Issues
Geometry challenges
Failure of equipment
Multiple blast cycles
High cycle time and labor intensive
Substrate damage is not an issue; must
remove corrosion and create surface profile

5. Past De-Painting Efforts
N-Methyl Pyrolidone
Pressure Stripper – 2001 (implemented)
Lactate Esters -2001
Turco 6776 – 2001
Ice Stripping – 2002
Electrostrip (CTC) – 2002
SERDP Depaint Project – 2003
Walnut Hulls
Alumina Zirconia
Plastic Media
Steel Shot
Flashjet
HP Water Blasting – 2000, 2006
Sponge Blasting – 2004 (implemented)
Tert Butyl Acetate (TBAc) – 2005
Cryogenic Paint Removal – 2005
Corn Hybrid (NDCEE) – 2006
ARL Surface Prep Project – 2006
Various (6) paint stripping products
EMMA Blasting – 2008
Laser Stripping (various funding programs) –
2001
2004
2008
2014
2016

6. Past Painting Efforts Numerous on-site demonstrations of CARC coatings
Joint Robotic Painting Project – Barstow – 2005
Partners – CTMA, ARL, Red River Army Depot (RRAD)
Automated Powder Coating Line (SERDP Project)
Conveyor line
Batch booth
Implemented Zinc Rich Primer (A-A-59745) on steel substrates
STAR4D painter trainer

7. Recent De-Painting Efforts
REPTECH PROJECT (FY16)
March – Project kick-off meeting with the REPTECH Program. Goal of the project is to conduct an on-site evaluation of all Paint and Coating (including blasting) equipment and processes to identify potential areas of modernization.
BLAST BOOTH RENOVATION (6)
Improved ergonomics (painting & lighting, new dust collectors)
Improved grit recovery system (augered entire floor)
Changed nozzles
ON-SITE DEMO
Preparing to conduct a trial demonstration of the new MIL-PRF Type III (interior)
Partnered with industry and the Army Research Lab
PAINTING
Changed over to conventional guns that are more compact light r with enhanced transfer efficiency.

8. Path Forward
MDMC will partner with various academic, industry and DoD research programs to identify available technologies that will provide automation, equipment upgrades and process improvements that will result in increased production, reduced labor costs, and less down time. Based upon the results of the upcoming REPTECH Project, MDMC will re-evaluate short term and long term strategies to meet these goals.

9. Questions?