NAVAIR Corrosion Program Overview and Recent Initiatives

Transcription

1 NAVAIR Corrosion Program Overview and Recent Initiatives Presented to: 06-June-2017 Air Force Corrosion Conference DISTRIBUTION A. Approved for public release: distribution unlimited. Presented by: Dane Hanson NAE CPT Future Readiness Lead 1

2 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 2 2

3 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: Safety Total Ownership Cost (TOC) Mission Readiness Service Life Management (SLM) 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 3

4 NAE CPT Organization NAE Board of Directors Engineering, Maintenance & Supply Chain Management (EM&SCM CFT) NAVAIR CPT Sustainment Logistics (AIR 6.7) Commander Naval Air Forces CPT Operational Logistics (N422) Current Readiness Corrosion Lead (AIR ) Future Readiness Corrosion Lead (AIR ) CNAF N422 (Plans and Policies) 4

5 FY17 NATEC C-MRT Distribution Pt Mugu (1) E-2 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 Lemoore (2) (5) F-18 Camp Pendleton (1) (2) H-1/V-22 Miramar (2) (3) C-130/H-53/F-18/V-22 North Island (1) (4) C-2/H-60 Whidbey Island (2) (3) P-3/P-8/EA-18G Yuma (1) (1) AV-8B Fort Worth (1) F-18/C-130 New Orleans (1) C-130/F-18/H-1 Stewart ANGB (1) C-130 Quantico (1) V-22 Jacksonville (1) (3) P-3/P-8/H-60 Beaufort (1) (2) F-18 McGuire AFB (1) H-1/H-53/C-130 Mayport (1) (1) H-60 NAF Washington (1) C-130 Norfolk (1) (3) (1) C-2/H-60/E-2/H-53/H-53(r)/ V-22(r) Oceana (2) (6) F-18 Cherry Point (1) (2) AV-8B/EA-6B/C-130 New River (1) (3) 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) FY-17 C-MRT End State NATEC FLEET NETs : (20) NATEC FLEET CETs: (46) NATEC RESERVE CETs: (7) 5

6 Current Readiness Team Priorities Policy: COMNAVAIRFORINST C, 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 6

7 Focus Area List Overview 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 Frequent Occurrence during major PMI events Chronic Corrosion Degraders Consumes largest maintenance resources Labor Hours Material Costs Large % of Total PMI Cost 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 7

8 FAL Item RCA & Mitigation FAL Item Root Cause Analysis & Mitigation using CPI Methodology Select FAL Item Discuss issues & agree on key contributors Categorize Issue/Competency Team Participation is paramount Training Tools, Materials Maintenance Plans ECP Policy Perform Root Cause Analysis Brainstorm mitigation strategies Select best mitigation strategy Create Action Plan Socialize, Refine & Publish Action Plan 8

9 NAE CPT Future Readiness Team 9

10 National Future Readiness Team 10

11 Future Readiness Team Site Alignment 11

12 FULL LIFE-CYCLE MANAGEMENT REQ Ts / RISKS FROM FLEET/ OPNAV MATERIEL SOLUTION ANALYSIS System Life Cycle Responsibilities FUTURE CAPABILITIES TECHNOLOGY DEVELOPMENT Acquisition Management Support ENGINEERING AND MANUFACTURING DEVELOPMENT CURRENT READINESS PRODUCTION & DEPLOYMENT OPERATIONS & SUPPORT PRODUCTS HEADQUARTERS / PEOs WARFARE CENTERS / DEPOT/ INDUSTRIAL SITES (FLEET READINESS CENTERS) TACTICAL AIRCRAFT CORE FUNCTIONS/ PROCESSES ACQUISITION MANAGEMENT Perform Acquisition Management For The Development, Production, And In-service Support Of Aircraft And Weapons Systems 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 AIR ASW, ASSAULT & SPECIAL MISSION 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 TEST & EVALUATION Test & Evaluate Aircraft, Weapons & Integrated Systems; Science & Technology For Test & Evaluation REPAIR & MODIFICATION Provide For The Repair And/ Or Modification Of Aircraft, Engines, Systems & Components UNMANNED AIRCRAFT & STRIKE WEAPONS COMMAND MANAGEMENT AND SUPPORT OPERATIONS Develop/ Maintain Competency Policies, Procedures & Support Services. Facilitate Effective Utilization Of Infrastructure, Security, Legal, Financial, Mgmt, Personnel & Info Resources 12 COMMON SYSTEMS/ MISSION SYSTEMS/ TRAINING/ ALRE

13 System Life Cycle Responsibilities 13

14 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) 14 14

15 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 , Corrosion Prevention and Control for Navy & Marine Corps Aviation Systems Assist RDT&E Transition Efforts 15 15

16 Corrosion Specs and Standards 16 16

17 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 17

18 FA-18 FAL Mitigation Example 18

19 FA-18 FAL Mitigation Example 19

20 Other Cross-Platform Priority Areas 20

21 Priority #1 Aircraft Interiors

22 Task 1.1 Lab Study 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

23 Task 1.2 Mildew Box Environmental Box to Study Mildew Growth Patterns 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 ) EMERGING BEST PRACTICES TO BE TRANSITIONED INTO THE MIL-STD-7179 AND/OR 01-1A 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. 23

24 Priority # 2 Electrical Wiring Interconnect Systems (EWIS) 24

25 Task 2 Lab Study 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 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???

26 Task 2 Lab Study Results Control versus One Commercial Product Applied to the Backshell Exterior EMERGING BEST PRACTICES TO BE TRANSITIONED INTO THE SAE AS12500 AND/OR 01-1A / 01-1A-505

27 Priority Area # 3 Aircraft Storage 27

28 Task 3 Field Study 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 EMERGING BEST PRACTICES TO BE TRANSITIONED INTO THE Approach: Evaluate the thermal- NAVAIR and UV-exposure EC 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

29 Hazmat Availability Improvement (HAI) Initiatives 29

30 HAI Initiatives Overview 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

31 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 modernization HAI Initiatives Scope Polysiloxane topcoats + Al-rich primers

32 Summary 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 Hanson NAE CPT Future Readiness Lead, Corrosion and Wear Branch Improved corrosion design will have the greatest impact over asset life cycle 32