1. Air Force Life Cycle Management Center
Acquisition Environmental and Industrial Facilities Division
Birthplace, Home & Future of Aerospace
EZVV Pollution Prevention Projects 17 Jan 18 Ms. Amy Mercado – Branch Chief
Ms. Karin Getschow P2 Lead; Omi Makhijani, and David E. Blair – P2 Project Managers
Acquisition Environmental & Industrial Facilities Division (AFLCMC/EZV)
DSN: / /
U. S. Air Force
DISTRIBUTION STATEMENT A – Approved for Public Release

2. Home Office – Wright-Patterson AFB, OH
AFLCMC/EN-EZ
Safety
Acq Env & Industrial Facilities Div
AF Industrial Plants
Acq Env & Health Risk Mgt Branch
Environmental Compliance and Restoration
Industrial Facilities
Pollution Prevention
ESOH Risk Reduction
Program ESOH Risk Mgt
Our Mission:
Promote effective ESOH integration & risk management practices
Implement pollution prevention processes and projects
Focused on support to the program offices!

3. Agenda
Who We Are
What We Do
Why We Are Here

4. AFLCMC-EZVV Hazard Risk Reduction Pollution Prevention (P2) Program
26 active projects value $10 million - JSF/C-130 at Industrial Plants
Identify and qualify solutions to mitigate hazards and provide business case analyses for implementation to AF program offices
Benefits
Reduces life cycle hazards, costs, and compliance burden from production, operation and sustainment, and disposal
Eliminate use of chromium and cadmium, where possible
Reduce HazMat used, and VOCs/HAPs emissions
Projects also support corrosion control goals—some eligible for inclusion in the DoD annual corrosion control report
A force multiplier for the Joint Strike Fighter and C-130 Programs to buy improvements while reducing pollution and risk

5. Air Force Plant 4 – F-35 Active Chrome Reduction Projects
Project Titles
Trivalent Chromium Anodize Seal Evaluation
Non-Hexchrome Fuel Tank Coating Replacement - F-35
Field Service Evaluation - Non-Chromated
Fuel Tank Coatings - F-35
Non-Chromium Tie Coat and Touch-up Primer Evaluation - F-35, F-16

6. SurTec 650V Trivalent Chromium Anodize Seal Evaluation
Objective - Elimination Hexchrome Sealer Dip Tank Process
Period of Performance – Jul 11 to Feb 18
Qualification Testing with SurTec 650V completed successfully
Coating Weight, Bare Aluminum Corrosion Resistance, and Wet Tape Adhesion -Successful performance
Wet Tape Adhesion with primers and fuel tank coating
PPG/Deft 02Y024, PPG/Deft 02GN084, PPG/Deft 44GN098, PPG/Deft 44GN036, Hentzen16708TEP/16709CEH, and Control PRC-DeSoto
Bare Corrosion resistance properties better than hexchrome control (Alodine 1200S)
Passed NSF, resistance to fluids, peel strength and coating weight , 6000, &
5000 alloys
All coupons passed 336 hours salt fog test - no pits
Corrosion resistance with coatings showed scratch resistance properties inferior
TCP Seal process sensitive – requires constant monitoring!
Immersion time critical
Temperature sensitive
Narrow pH – monitoring crucial
Filtering solution required periodically
Concentration percent SurTec650V monitored periodically
Path Forward
Shop trials – Began fall 2017
Seal contamination study – In progress

7. Non-Hexchrome Fuel Tank Coating Replacement, F-35
Objective - Qualify Non-Hexchrome Fuel Tank Coating (FTC) - F-35
Period of Performance - Apr 14 through Apr 18
Control - PRC Hexchrome FTC
Non-hexchrome Candidates
PPG RW
Top performing candidate
Akzo Nobel XP more difficult to apply
Akzo Nobel XP (5021FT001)
Performing well but recurring marginal adhesion issues on Chem-Film
AMS-C Requirements: 100% Complete
All candidates failed DiEGME AMS test – 165⁰ F/60 days
Program specific testing – 80% complete - Beach, neutral/acidic salt fog, galvanic corrosion
Production simulation shop trials started 2017
Puffer box testing – simulated fuel tank testing planned
Encourage vendors pursue AMS-C qualification
PPG RW-7088 submitted Jul 16
3 yr. Field Service Evaluation – In progress – began late December 2017

8. Non-Hexchrome Tie-Coat and Touchup Primer Evaluation - F-35, F-16
Objective – Implement non-hexchrome repair primer
Period of Performance – Apr 14 to Apr 18
Application process – spray or brush
Current Status:
Touch-up primer candidates
Akzo Nobel XP554-34B (Leading candidate)
Supplier changed inhibitive pigment
Re-verify performance - 90% complete – performance similar control
Brush application - better flow properties and induction time
Deft/PPG 02GY097 (Failed low temp. flexibility and repairability tests)
Fuel tank compatibility – Complete – passed F-35 - AMS-3277/3281
Program specific testing – 30% complete/70% in work
Production level shop trials – Jan 18 to Aug 18

9. AFP6 Pollution Prevention Active Projects
Project Titles
Qualify Low or Non-Hexchrome Sealant Alternatives for
C-130J Inner Mold Line
Qualify Complete Non-Hexchrome Finish Systems, Alternative Extended Life Topcoats, C-130 J
Qualify Non-Hexchrome Fuel Tank Coating,
C-130J Integral Fuel Tank
Qualification of Non-Hexchrome Inner Mold
Line Finish on C-130J
Qualification of Non-Hexchrome Anodize Sealer for
Sulfuric Acid Anodized Component parts, C-130J
Qualify a Chrome-Free Primerless, Drop-In
Replacement Coating for C-130J
AFP = Air Force Plant

10. Qualify Low or Non-Hexchrome Sealant Alternatives - C-130J IML
Objective – Qualification testing - five previously identified non-hexchrome sealant candidates
Period of Performance – Apr 15 to Jun 18
C-130 J Faying surface sealing and wet installation fastener operations
Based on success - final phase - do field evaluation and engineering implementation
Current Status:
Application property testing complete (Appearance, viscosity, cure time, specific gravity, volume swell)
Performance property testing in-work (Peel strength, paintability, galvanic corrosion)
Evaluating test results/data analysis
Five Candidates:
AC-735 (3M), PR-1775 (PPG), PR-2870 (PPG), CS 5500N Cl (Flamemaster) and WS8033 (Royal)
Potential - reduce ~3500 lbs/yr hexchrome containing sealant and contaminated waste
IML = Inner Mold Line (Inside Aircraft)

11. Qualify Complete Non-Hexchrome Finish Systems, Alternative Extended Life Topcoats, C-130 J
Objective – Qualification testing - alternative extended life topcoat products and finish systems
Period of Performance: Apr 18 – Apr 19
Qualified to MIL-PRF-85285, Type IV, Class H
Pair EL topcoats with successful non-hexchrome conversion coating/non-hexchrome primer combinations identified earlier AF funded P2 projects
Avoids sole-supplier condition for exterior topcoats
Eases implementation non-hexchrome finish system
Provides finish systems favorable C-130 paint personnel
Potential reduce volatile organic compound emissions
Current Status:
Work already started at Plant 6

12. Qualify Non-Hexchrome Fuel Tank Coating, C-130J Integral Fuel Tank
Objective - Qualification - off-the-shelf non-hexchrome Integral Fuel Tank (IFT) coatings
Period of Performance – Apr 16 to May 19
Develop Implementation Plan and Business Case Analysis
Current Status:
Vendors lowering VOC from 720 to 420 g/l - slight testing delay
Candidate samples received from three vendors
Qualification testing on-going
Vendor identified issue
Storage stability/pot life vendor corrected – 2 candidates
Submit fresh samples
Potential - reduce 200 lbs hexchrome annually

13. Qualify Non-Hexchrome Inner Mold Line Finish - C-130J
Objective – Qualify commercially available non-hexchrome IML pretreatment and primer
Period of Performance – May 17 to Nov 20
Implement Inner Mold Line (IML) finish completely hexchrome free
Includes Implementation Plan and Business Case Analysis
Current Status:
Testing includes insoluble matter residue rinsability
Production level shop trials include cleaning ability with oil, lubricants – dirty tests
5 pre-treatment candidates selected
8 non-hexchrome primers selected
Potential - reduce ~2100 lbs/yr
hexchrome from IML

14. Qualification of Non-Hexchrome Anodize Sealer for Sulfuric Acid Anodized Component Parts - C-130J
Objective – Qualification suitable non-hexchrome sealers
Period of Performance – May 17 to Dec 20
Component parts include wing panels, floor panels, engine truss mounts, bilge area parts, assorted wing components, etc. for high corrosion protection.
Overall performance, material compatibility, corrosion resistance and primer adhesion
Includes pre-implementation engineering
Current Status:
Testing ongoing

15. Qualify Hexchrome-Free Primerless Drop-In Replacement Coating - C-130J
Objective – Qualify hexchrome-free, primerless coating systems for aircraft outer mold lines (OML)
Period of Performance: Oct 17 to Apr 19
Eliminate hexavalent chromium from coating stack-up
Eliminate primer application step = weight reduction
Current Status:
Initial Screening tests (7 hexchrome-free surface treatments, 3 hexchrome-free multi-functional topcoats; total 21 coating systems)
Completed – 10 coating systems down-selected - Phase II testing
Humidity resistance, heat resistance, solvent resistance, adhesion, low temperature flexibility
Completed In-Depth testing - included fluids resistance & outdoor exposure
3 coating systems down-selected - Phase III
Gardobond AP 9811/PPG 97GY160 (AMC)
Aculon OP-272/PPG 97GY160 (AMC)
AC-131BB/PPG 97GY160 (AMC)
Qualification testing – Application & Compatibility Study, and 2000 hr. salt fog
Preparation & planning FSE - multiple platforms/aircraft
Update Cost Benefit Analysis (CBA)

16. AF Life Cycle Management Center
Thank you!
U. S. Air Force
Acquisition Environmental & Health Risk Management Branch (AFLCMC/EZVV)
(DSN )
(DSN )
DISTRIBUTION STATEMENT A – Approved for Public Release