Presented to:

Presented by:

NAVAIR Corrosion Program Overview and

Recent Initiatives

Air Force Corrosion Conference

Dane Hanson

06-June-2017

NAE CPT Future Readiness LeadDISTRIBUTION A. Approved for public release: distribution unlimited.

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NAE Corrosion Impacts

➢ The impacts of corrosion to the NAE are significant

▪ Accounts for over $3.6B annually = 27% of all aviation maintenance support cost

▪ Reduced operational availability and mission readiness of NAE aircraft

▪ Unpredictable maintenance budgets, scheduling & execution

▪ Reduced effectiveness of lifecycle logistics support systems

▪ Degraded A/C Service Life Management (SLM) programs

➢ Improving aircraft corrosion abatement efforts throughout the NAE is

essential to minimizing these impacts

Based on 2014 LMI Cost of Corrosion study

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Safety Mission Readiness

Total Ownership Cost (TOC) Service Life Management (SLM)

NAE Corrosion Prevention Team

➢ Chartered 2007: CNAP N42, NAVAIR, FRC, Platform FST/ISSC & Fleet

corrosion SME

➢ Prime Objective: Improve airframe material condition through systemic

corrosion abatement strategies to reduce corrosion impacts to:

➢ Strategy: Reduce NAE platform corrosion support cost & improve aviation

readiness through four Strategic Objectives:

Data: Improve corrosion maintenance

data reliability for decision makers

Policy: Improve corrosion policy,

communication & abatement strategies

Training: Build and sustain platform

centric, core material condition

maintenance capability

Engineering: Resource technologies to reduce

corrosion and related costs

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Commander Naval Air Forces CPT Operational Logistics

(N422)

NAVAIR CPT Sustainment Logistics

(AIR 6.7)

NAE Board of Directors

Engineering, Maintenance & Supply Chain Management (EM&SCM CFT)

NAE CPT Organization

Future Readiness Corrosion Lead (AIR 4.3.4.6)

Current Readiness Corrosion Lead (AIR 6.7.2.1)

CNAF N422 (Plans and Policies)

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FY17 NATEC C-MRT Distribution

FY-17 C-MRT End State

NATEC FLEET CETs: (46)

NATEC FLEET NETs : (20)

NATEC RESERVE CETs: (7)

Norfolk (1) (3) (1)

C-2/H-60/E-2/H-53/H-53(r)/

V-22(r)

Cherry Point (1) (2)

AV-8B/EA-6B/C-130

Stewart ANGB (1)

C-130McGuire AFB (1)

H-1/H-53/C-130

NAF Washington (1)

C-130

Quantico (1)

V-22Oceana (2) (6)

F-18

New River (1) (3)

H-1/H-53/V-22Beaufort (1) (2)

F-18

Jacksonville (1) (3)

P-3/P-8/H-60

Mayport (1) (1)

H-60

New Orleans (1)

C-130/F-18/H-1

Whidbey Island (2) (3)

P-3/P-8/EA-18G

Lemoore (2) (5)

F-18Pt Mugu (1)

E-2

Camp Pendleton (1) (2)

H-1/V-22

North Island (1) (4)

C-2/H-60

Yuma (1) (1)

AV-8B

Miramar (2) (3)

C-130/H-53/F-18/V-22

Fort Worth (1)

F-18/C-130

Kaneohe Bay (1) (2)

H-1/H-53/H-60/P-3

Atsugi (1)

H-60

Iwakuni (1) (3)

F-18/E-2/EA-18G/C-130

Okinawa (1) (1)

H-1/H-53/V-22

C-MRT Transition to NATEC➢ FY17 C-MRT End State in place MAR17

➢ Combined all C-MRT efforts under NATEC management.

➢ End of FY 17 Planned: ➢ Add 11 C-MRTs with additional focus OCONUS

➢ Japan (+6) and Hawaii (+2)

Current Readiness Team Priorities

• Policy: COMNAVAIRFORINST 4790.2C, “The Naval Aviation

Maintenance Program (NAMP)” (REVISION PUBLISHED IN 2017)

• Fleet: 01-1A-509, “Cleaning and Corrosion Control” General Series

Manual or platform-specific repair manual

• Data: Improved data quality by improving inspection processes and

ratings, data capture means, malfunction codes and pilot assessments

of hand-held device for entering data during inspections – Automated

Data Capture System

• Training: “Corrosion Control for Managers” course, Wing MCI and FAL

training, “A” School corrosion curriculum updates

• Communication: Corrosion Maintenance Readiness Team (C-MRT),

Corrosion Fleet Focus Team (CFFT), and platform FST/CPAT

involvement with fleet, depots, and OEMs

• Deficiencies: Focus Area Lists (FAL) & Root Cause Analysis (RCA) –

focused effort in FY16-17 to identify and resolve documented corrosion

degraders

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Focus Area List Overview

FALs are a major part of the NAE’s corrosion mitigation strategy because they:

• Provide robust communication between RCM ISSCs/FST, Depots and O-level

• Promote innovation in tools, materials and techniques

• Focus & align TMS specific corrosion prevention, detection & treatment in the Fleet

• Provides business case/RCM criticality analysis for logisticians and maintainers to prioritize

resources on problematic corrosion prone areas

The Focus Area List (FAL) is an FST developed list of the top 20 percent of

platform corrosion degraders

The FAL is derived from all

Level 3 Corrosion Related

workload documented during

PMI events

• Chronic Corrosion Degraders

• Labor Hours• Material Costs• Large % of Total PMI Cost

Frequent

Occurrence

during major

PMI events

Consumes

largest

maintenance

resources

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FAL Item RCA & Mitigation

FAL Item Root Cause Analysis & Mitigation using CPI Methodology

Perform Root Cause

Analysis

Brainstorm

mitigation strategies

Socialize, Refine &

Publish Action Plan

Create Action PlanSelect best

mitigation strategy

Select

FAL Item Discuss issues & agree on

key contributors

Categorize

Issue/Competency

Team

Participation

is paramount

TrainingTools,

MaterialsMaintenance

PlansECP Policy

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NAE CPT Future

Readiness Team

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National Future Readiness Team

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Future Readiness Team Site Alignment

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CORE FUNCTIONS/ PROCESSES

FULL LIFE-CYCLE MANAGEMENT

System Life Cycle Responsibilities

HEADQUARTERS / PEOs

WARFARE CENTERS / DEPOT/ INDUSTRIAL SITES (FLEET READINESS CENTERS)

OPERATIONS &

SUPPORT

PRODUCTION &

DEPLOYMENT

ENGINEERING AND

MANUFACTURING

DEVELOPMENT

TECHNOLOGY

DEVELOPMENT

FUTURE CAPABILITIES CURRENT READINESS

MATERIEL

SOLUTION

ANALYSIS

S&T, R&D, HARDWARE, SOFTWARE PRODUCTS, DESIGN

Conduct Efforts Focused On The Advancement Of Science, Technology, Research And

Development And Delivery Of Hardware/ Software Products

IN-SERVICE ENGINEERING & LOGISTICS SUPPORT

Analyze System Data, Determine / Implement Corrective

Actions To Sustain In-service Systems And To Ensure

Safety, Affordability, And Availability; Perform Engineering

Investigations, Engineering Change Proposals

ACQUISITION MANAGEMENTPerform Acquisition Management For The Development, Production,

And In-service Support Of Aircraft And Weapons Systems

COMMAND MANAGEMENT AND SUPPORT OPERATIONSDevelop/ Maintain Competency Policies, Procedures & Support Services.

Facilitate Effective Utilization Of Infrastructure, Security, Legal, Financial, Mgmt, Personnel & Info Resources

PRODUCTS

TACTICAL AIRCRAFT

UNMANNED AIRCRAFT & STRIKE WEAPONS

COMMON SYSTEMS/ MISSION SYSTEMS/ TRAINING/ ALRE

AIR ASW, ASSAULT & SPECIAL MISSION

REQ’Ts / RISKS

FROM FLEET/

OPNAV

TEST & EVALUATIONTest & Evaluate Aircraft, Weapons & Integrated Systems; Science & Technology For Test & Evaluation

REPAIR & MODIFICATION

Provide For The Repair And/ Or Modification Of

Aircraft, Engines, Systems & Components

Acquisition Management Support

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System Life Cycle Responsibilities

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Future Readiness Team Priorities

• Complement Existing Sustainment Efforts Identify resource constraints within the PMA and/or FST

Complement teams – e.g. CAT, CPAT, CPAB, CCWG – where team members already have a presence

• Improve Material Availability for Field Corrosion Control Identify sole source, long lead time, short shelf life hazardous materials

Evaluate mitigation to identify equivalent alternatives, improving procurement processes, or extending shelf lives

• Establish feedback loop between legacy aircraft and new acquisition (H-53E H-53K, E-2C E-2D)

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Future Readiness Team Priorities

• Implement Corrosion Control Design “Best Practice” and Modernize Based on CPT-Validated M&P

MIL-STD-1568, “Materials and Processes for Corrosion Prevention and Control in Aerospace Weapons Systems”

MIL-STD-7179, “Finishes, Coatings, and Sealants, for the Protection of Aerospace Weapons Systems”

SAE-AS-12500, “Corrosion Prevention and Deterioration Control in Electronic Components and Assemblies

NAVAIR EC-434-000-005, “Corrosion Prevention and Control for Navy & Marine Corps Aviation Systems”

• Assist RDT&E Transition Efforts

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Corrosion Specs and Standards

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NAVAIR Corrosion Engineering Circular

• Content

– Volume 1: Acquisition

• Program CPC Guidance

• System Design CPC Contract Language

• CPC Trade Study Information

• Corrosion Verification and Validation

Criteria

• CPC Program Assessment

– Volume 2: Sustainment (in progress)

• CPC Lessons Learned

• Impact of Corrosion on NAE

– Appendix

• Corrosion Airworthiness Requirements

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FA-18 FAL Mitigation Example

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FA-18 FAL Mitigation Example

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Other Cross-Platform

Priority Areas

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Priority #1 – Aircraft Interiors

• SERDP WP-2747, “Mechanistic Study of Fungi Degradation of Organic Coatings

used in Aircraft Finish Systems”

• Problem Statement:

Aircraft are exposed to extreme environmental conditions – heat, humidity, salt,

operational fluids, etc.

Microbes in hot/humid environments feed off of organic materials – coatings,

CPCs, hydraulic fluids, etc.

Aircraft interiors receive limited-to-no exposure to UV-light to disable growth of

microbes

Aircraft interiors are equipped with complex wiring, hydraulics, and avionics

systems that make cleaning and treatment difficult

• Approach:

Prepare standard and novel finish systems and expose to microbes

Identify which components retard microbe attachment and proliferation

Design new finishes incorporating low surface energy or biocidal additives to

finish aircraft to avoid costly and time-intensive remediation operations and

prevent exposure to microbe spores – breathing hazard

Task 1.1 – Lab Study

Task 1.2 – Mildew Box

1450 Black Pelican Box

Water Tight filled with Fluid

to increase Humidity.

Water reservoir in the bottom of the

box just below the perforated sheet

(Approx 3.5”)

Note: Box will have holes around

the perimeter to allow for spore entry and

circulation. Need to identify the minimum

sized holes which will allow free entry while

minimizing unwanted entry and moisture

loss.

Environmental Box to Study Mildew

Growth Patterns

EMERGING BEST PRACTICES TO BE TRANSITIONED INTO

THE MIL-STD-7179 AND/OR 01-1A-509-2

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Priority # 2 – Electrical Wiring

Interconnect Systems (EWIS)

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• Problem Statement:

Aircraft are exposed to extreme environmental conditions – heat,

humidity, salt, operational fluids, etc.

EWIS in SWaMP (Severe Weather and Moisture Prone) areas exhibit

high rates of degradation

Even with current authorized materials, EWIS still corrode over time

A comprehensive study of potential EWIS finishing options has never

been completed to characterize cost / time versus benefits

• Approach:

Prepare standard and novel finish systems and expose to simulated

environmental conditions – ASTM B117, ASTM G85-A4, GMW 14872

Identify which finish options efficiently delay the initiation of corrosion and

inhibit performance degradation

Balance intensiveness of the process versus the benefit achieved – what

is achievable in the field with the time and materials available???

Task 2 – Lab Study

• Control versus One Commercial Product Applied to the Backshell

Exterior

Task 2 – Lab Study Results

EMERGING BEST PRACTICES TO BE TRANSITIONED INTO

THE SAE AS12500 AND/OR 01-1A-509-3 / 01-1A-505

Priority Area # 3 – Aircraft Storage

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• Problem Statement:

Aircraft are exposed to extreme environmental conditions – heat,

Ultraviolet light, inclement weather, etc. – during operations and storage

Environmental factors contribute to degradation to non-metallic materials

that are used on aircraft and produce difficult working environments for

regular aircraft maintenance

Some operational units have Aircraft Protective Equipment (APE) to

reduce degradation rates and provide satisfactory working conditions

A cost-benefit analysis of the benefits of APE has not been performed to

justify their usage beyond current units

• Approach:

Evaluate the thermal- and UV-exposure of aircraft substrates on Summer

days at known prone locations – both exposed and covered by APE

Assemble database of non-metallic materials on aircraft and their thermal

stability / activation energy / susceptibility to UV

Track rates of degradation of aircraft materials through known databases

Task 3 – Field Study

EMERGING BEST PRACTICES TO BE TRANSITIONED INTO

THE NAVAIR EC-434-000-005

Hazmat Availability

Improvement (HAI)

Initiatives

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• Problem Statement:

Hazmat are necessary for accomplishment of routine / scheduled

maintenance and un-scheduled repair

Hazmat availability is compromised due to SHORT material shelf life,

LONG lead time, SOLE source, MINIMUM purchase quantity, etc.

• Approach:

Determine the root cause of material non-availability by discussion with

stakeholders (e.g. Environmental Logistics, Purchasers, Users, Suppliers)

Brainstorm alternatives to circumvent or eliminate the major root causes

Modify conditions and evaluate performance of hazmat after exposure to

test conditions

HAI Initiatives Overview

• Extended shelf life of touch-up

applicators

• Non-Chromate 2-component aerosols

• TT-P-1757 modernization

• Epoxy primer re-activators

• Reduced VOC Non-Chromate primers

for Ground Support Equipment (GSE)

• MIL-T-81772 modernization

• Polysiloxane topcoats + Al-rich primers

HAI Initiatives Scope

Summary

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• Corrosion is a significant cost, service life, and availability degrader

• The Naval Aviation Enterprise Corrosion Prevention Team is attacking corrosion in all phases of the weapon system life cycle

• Dane HansonNAE CPT Future Readiness Lead, Corrosion and Wear Branch

Improved corrosion design will have the greatest impact over asset life cycle