SERDP and ESTCP have launched a webinar series to promote the transfer of innovative, cost-effective and sustainable solutions developed through projects funded in five program areas. The webinar series targets Department of Defense and Department of Energy practitioners, the regulatory community and environmental researchers with the goal of providing cutting edge and practical information that is easily accessible at no cost.

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Webinar #27 (02/11/2016)

Chromate/Hazardous Material Free Coating Systems for Military Aircraft and Ground Support Equipment

Ms. Julia Russell (Naval Air Systems Command)

Ms. Brenna Lynn Skelley (Naval Air Systems Command)

Mr. Michael Spicer (U.S. Air Force Coatings Technology and Integration Office)

Presented February 11, 2016 

Webinar Slides

Webinar Topics 

Non-Chromated Paint Primers by Ms. Julia Russell and Ms. Brenna Lynn Skelley

Non-chromated primers need additional maturation and validation to be more thoroughly and rapidly implemented on Department of Defense (DoD) weapon systems. The objectives of ESTCP project WP-201132 are to: provide an overarching assessment of the current state of the art; support the maturation of promising products; field test mature products; document organization-specific assessment and implementation requirements; and revise specifications to account for new products. The project brings together users from Army Aviation and Ground, Navy Air and Ships, Air Force, Marine Corps Ground and Amphibious, Coast Guard, and NASA to establish application needs, as well as target laboratory assessments and field tests to provide sufficient data to make implementation decisions for new non-chromated primers. Validating the equipment, process, and coating are key. For example, newer technologies like e-coat and force cured (ultraviolet, infrared, thermal) resins require additional equipment to deposit or cure the coating. Projects of these types are therefore more complicated and generally more expensive than those focused on improved traditional spray paint-based primers. For use across DoD organizations, alternatives need to be characterized as stand-alone products that can be implemented on a variety of different surfaces, and topcoated with a variety of different materials and within prescribed coating systems – which are qualified and used in particular combinations. Expected benefits include increased and more rapid implementation of non-chromate primers on DoD weapon systems by DoD users during maintenance, and by original equipment manufacturers and sub-contractors during design and construction of new equipment.

Non-Chromate Outer Moldline (OML) Coating System Transition Effort by  Mr. Michael Spicer

In order to comply with environmental and workplace regulations, the U.S. Air Force is striving to replace chromate containing corrosion protection systems. Eight complete non-chromate coating systems have been evaluated against two chromate coating systems using extensive outdoor exposure testing at Daytona Beach and Tyndall Air Force Base. The results suggest that the best of the non-chromate coating systems actually offer superior performance compared to the environmentally problematic chromate containing coating systems. Non-chromate coating systems have been utilized by the U.S. Air Force on the F-15 fleet since January 2012, by the Norwegian Air Force since January 2012, on German Tornados and P3-C Orions since May 2012, and on Italian C-130s since July 2012. The U.S. Air Force is utilizing an enterprise approach to expedite the adoption of non-chromate corrosion protection systems throughout the fleet where applicable. Air Force senior leaders have endorsed non-chromate coating systems and recommended the development of implementation plans. The Corrosion Prevention and Control Office, Air Force Research Laboratory Coating Technology Integration Office, Air Logistical Centers, and paint manufacturers will participate in the non-chromate transition, including classroom time and hands-on training. The Air Force is minimizing risks inherent in the introduction of new materials by first applying the new, non-chromate coating systems on low corrosion-prone aircraft based in low corrosion environments (which began in March 2014). The implementation team will determine if implementation should then be extended to moderate corrosive environments and less corrosion-resistant systems after reviewing two year results. 
 

Speaker Biographies

Ms. Julia Russell is the Science and Technology Lead of AIR-4.3.4.2 (the Industrial Processes Branch) of the Naval Air Warfare Center, Aircraft Division (NAWC-AD), where she has been an employee since 2005. Ms. Russell’s focus is on strategic investments in maturing coatings, sealants, and adhesives technology areas as they align with Naval Aviation Enterprise Science and Technology goals. She is a Principal Investigator of various research development test and evaluation efforts including ESTCP project WP-201132. She has a Bachelor of Arts degree in Chemistry from St. Mary’s College of Maryland.

Ms. Brenna Lynn Skelley is a chemical engineer working in the materials engineering division at the Naval Air Warfare Center, Aircraft Division, Patuxent River, Maryland. She is a member of the organic coatings team and her focus areas are primer and topcoat formulation, as well as coatings testing and evaluation with a particular emphasis on polysiloxane topcoats and aluminum rich primers. She completed a rotational assignment at the Naval Research Laboratory (NRL) in Washington in 2014, and has been involved in multiple research and development efforts during her time at NAWC-AD. She received a Bachelor of Science degree in chemical engineering from the University of Maryland.

Mr. Michael Spicer is currently the Chief of the Air Force Coatings Technology and Integration Office (CTIO), which is an ISO 17025 and AS5505 certified laboratory serving as the Air Force’s central resource for aircraft coating systems and their applications. Mr. Spicer has been performing research development test and evaluation on organic and inorganic coatings at the CTIO since 1992. He has been an employee of the U.S. Air Force since 1987. He has a Master of Science degree in Materials Engineering and a Bachelor of Arts degree in Computer Engineering from the University of Dayton. 

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