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Slide 1
Topcoat
Chromate Primer
Chromate Conversion Coating
substrate
Topcoat
NonChromate Primer
NonChromate Conversion Coating
substrate
Topcoat
Chromate Primer
NonChromate Conversion Coating
substrate
substrate
Adhesion Promoters
Dont meet MIL-C-81706
Key Performance Goal: Long Term Corrosion Protection Coating system: 2000+ hours neutral salt fog
Conversion coating: 168 hours
Slide 2
Specification coverage
Technical Order / Military or industry specifications Current specification limits Equal or better than todays coating systems
Slide 3
Overview
AACP program
Goals AC-131/Boegel Performance data Producibility data
Other applications
Painting Bonding
Slide 4
Program Description
Funded by Aging Systems Command/AFRL
Aging Aircraft Office (ASC/AAAV)
Topcoat technologies developed for C-17 (APC) Nonchromate Conversion Coating technologies developed by AFOSR/AFRL/DARPA (Boegel/AC-131) Phase I: Laboratory validation of performance and process Phase II: Flight test
Coat test vehicles, summer 2004
Program Plan
Deliverables:
Coating system description Laboratory validation data Analysis of flight testing Processing description for T.O. 1-1-8
Slide 5
Flight Operations
Depaint
Depot Maintenance
Repaint
Repaint
Clean & Seal Alkaline Clean Brighten Conversion Coat
(AC-131) (Cr primer, APC Topcoat)
Slide 6
Slide 9
Mixed Zr/Si oxide system Silane coupling agent chosen to match primer, sealant, or adhesive chemistry Water solution -- ~3-5% solids Spray on, no rinse, ambient dry Little or no waste
Neutralize and sewer
AC-131/Boegel-EPII is epoxy functionalized epoxy primers/adhesives Boegel-AM is amino functionalized polyimide adhesives
Superior adhesion
Slide 10
AC-131/Boegel EPII
Optimized for adhesion of epoxy coatings
Superior adhesion to Al, Ti, CRES
Slide 11
Replacement for Alodine 1000 Meets production engineering reqmts on new clad aluminum fuselage
Ability to mix and use Process compatibility with masking and equipment Ability to Strip Paper/Tape compatibility Compatibility over Composites
Rain Erosion Forward and Reverse Impact Acrylic Crazing Titanium Stress Corrosion Hydrogen Embrittlement
2004 Air Force Corrosion Program Conference
Slide 12
Inspectability of Boegel/AC-131
Dyes and fluorescents Good color definition with dyes No effect on adhesion performance Weatherability/cleanability data to be developed
AC-131
Alodine 1200S
Slide 13
Stretch Goal
Eliminates chromate conversion coating Eliminates brightener step and associated rinses Shows promise need to define cleaning process
2004 Air Force Corrosion Program Conference
Slide 15
Depainting
Does not depaint like conventional systems
Topcoat removes first from primer Additional dwell time or manual effort needed to remove primer
Alodine / MIL-PRF-85582 Boegel EP II / MIL-PRF-85582
Alodine / MIL-PRF-23377
Boegel EP II / MIL-PRF-23377
25
20
AA2024
Hours (80-100% Primer Removal)
Boegel EP II / MIL-PRF-23377 Boegel EP II / MIL-PRF-85582
15
10
25
20
Ti 6,4
0
PR 3133 (Ammonia) PR 5044 (Peroxide) PR5000 / PR3170 (Peroxide / Solvent) TRP Inc. ES-1 (MeCl2 / Formic Acid)
15
10
0
PR 3133 (Ammonia) PR 5044 (Peroxide) PR5000 / PR3170 (Peroxide / Solvent) TRP Inc. ES-1 (MeCl2 / Formic Acid)
Slide 16
Boeclene/Boegel/ 85582/APC-g
BB82G
Boeclene/Alodine 10PW22-2/APC-g
BA10G
Slide 18
BA82G
Slide 19
Slide 20
Deft 03-GY-321
8 7 6 5 4 3 2 1 0
Akzo 10P20-4/ ECW-104
March 8-11, 2004
Deft 99-GY-001
60 85 DeltaE
Deft 02Y040
Deft 44GN72
SW E90G203
Deft 02Y040
Deft 44GN72
PRC 1432GV
SW E90G203
Slide 21
Specification Summary
Spec #
BAC5663
Process
Aluminum Alloy Conversion Coating for Paint Titanium Alloy Conversion Coating for Paint Titanium Alloy Adhesive Bonding
Implementations
BCA-Fuselage rivets (737 console) (final paint) F-22
D950-10313-1, Rev C; BSMS25-002; BSPS-07-002 BSMS-25-001; BSPS-07-001, HP 4-136 Rev A; D950-10413-1 Rev A, D720PM-PP006, Rev A; S697-10090-1 Rev A; 5PTPHB25; Assorted DoD TOs D210-13577-1; SRM 51-70-09; SRM 51-70-10; Assorted DoD TOs HP 4-136 MRB
F-22; X-32; B-2 spares; Delta IV; AH-64; F-22; CH-47; CH-46
Slide 22
Depainting
AC-131
Rain Erosion
AC-131 coated
HF/HNO3 etch
Phosphate fluoride
Boegel
Current:
Slide 24
Titanium bonding
B-2 Ti core to composite
Aft Boom composite reinforcement Studs for insulation blanket installation Repair/reinforcement of structure
Slide 25
BAC5663 Released
Implementation Strategy
Probably drawing change
Slide 26
Standard Work Sheet From: Raw Material to finished painted part and in To: Stores in two days
9/20/02
Supervisor
737
Clean
C/T 1 min
Drill Tap
C/T 10 min
Straighten
C/T 1 min
Tab Removal
C/T 5 min
in coming from T-20 134 minutes for first part through the line Total touch time = 74 minutes Planning standards = 29 minutes
C/T 2 min
Customer Requirements Takt Time = 137 Min. 70 Parts Per Month Daily Requirement 3.5 Parts 737 Monthly Rate 14 Planes
Penetrant
C/T 2 min
C/T 2 min
Boe-gel Dwell location
C/T 2 min
Hand Finish
Part Mark
out going
Sand blast
Mask
Boe-gel application
Paint Booth
Goals
27 flow days reduced to 2 days @ a one shift operation 2nd shift operation available for additional part numbers
= ship set
Boe-gel rest time = 60 min
Quality Check
Safety Precaution
TAKT Time
Operator Number
Slide 27
TF-33 cowl
Titanium panels, stainless rails, aluminum brackets Cleaned to WBF, coated, 2 hour dry, prime Racked for painting, coated, 2 hour dry, prime
Slide 28
Conclusions
AC-131/Boegel EPII coating systems are capable for depot and field processing environments
Performance equivalent to present systems
Chromated primer is still required
Superior adhesion to aluminum, titanium, and stainless steel Colored for process and in-process and end-item inspection Potential to eliminate aggressive brightening Potential to provide stand-alone corrosion protection
Ongoing inhibitor incorporation work.
Flight testing in AACP program will validate performance capabilities for mold line use
Language for T.O. 1-1-8 for implementation