Hexavalent Chromium and Sustainability of Surface Treatment Processes at the Corpus Christi Army Depot. An AMCOM Force 2025 Transition Plan Initiative

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1 Hexavalent Chromium and Sustainability of Surface Treatment Processes at the Corpus Christi Army Depot An AMCOM Force 2025 Transition Plan Initiative ASETS Defense Workshop December 6, 2016 Mark Feathers Lead Environmental Engineer Sustainable Chemicals and Materials AMCOM G-4 Environmental Division

2 Overview Cr6 + and the Risk to AMCOM Cr6+ Risk Mitigation Strategy Implementation Approach Technology Transition Agreement (TTA) Summary 2

3 Evolution of the Cr6+ Risk Issue 1989 IARC Designates Cr6+ as Human Carcinogen 2005 National Toxicology Program 11 th Annual Report to Congress: Cr6+ is a Human Carcinogen 2006 OSHA Lowers Cr6+ PEL from 52 to 5 (µg/m³ 2009 USD(ALT) Releases Memo to all Military Departments Directing Investment into Alternative Technologies Cr(VI) compounds restricted by REACH without specific Authorization 1998 EPA Risk Assess Cr PGE $235 Million Settlement 2006 DOD Complete Cr6+ Risk Assess- O&M Risk is High 2012-Army Environmental Requirements and Technology Assessment, PP Toxic Metal Reductions in Surface Finishing Processes Validated by ACSIM 3

4 Obsolescence What Does the Hexavalent Chromium Risk Mean to AMCOM? Regulatory pressure (OSHA, ACGIH or EPA) Potential scenarios: EPA bans Cr6+ in certain applications via Toxic Substances Control Act (TSCA) or OSHA/ACGIH lowers the exposure limit to unsustainable levels OEMs competing in a global environment impacted by EU regulation entitled Registration, Evaluation, Authorisation and Restriction of Chemicals (REACH) Suppliers/vendors moving away from Cr6+ products Cr6 + is very prevalent in the CCAD Plating Shop Cr6+ found in 39 out of 215 (18%) active tanks in the plating shop Critical processes: anodizing, sealing, conversion coating, plating and passivation 400+ unique parts receive Cr6 + surface treatments Takes 5-10 years to develop, test, demonstrate and implement a new alternative process BOTTOM LINE: Cr6 + obsolescence + prevalence of Cr6 + coatings on components + duration to implement alternative process= high risk to sustainability of the AMCOM mission 4

5 Toxic Metal Reduction (TMR) Program Created to Address Cr6+ in the CCAD Plating Shop % Cr6 + Reduction # of Unique Parts Test & Demo Schedule*** Project (Lab/Demo/Implementation) Cr 6+ -Free Hard Chrome Electroplating (TMR 14-01, AMCOM) and SBIR for stripping* (Faraday) FY14-22 Cr 6+ -Free Aluminum Anodizing (TMR 15-01, AMCOM) (Sikorsky) FY15-20 Cr 6+ -Free Surface Activation and Preparation for Metal Plating (TMR 13-03, ARL) (anodize stripping) FY14-19 Cyanide-Free Cu and Ag Electroplate (TMR 15-02, AMCOM-CCAD) 5 34 FY15-19 Cr 6+ Free Passivation of Stainless Steel (DO 0001, NDCEE) (E2A) FY16-20 Tagnite Anodizing as a Replacement for Magnesium Conversion Coating (WP , ARL) (TAG) FY14-20 Cr 6+ -Free Conversion Coatings (TMR 14-02, ARL) 8 TBD FY14-20 Cr-Free Sealers for Legacy Coatings (TMR 16-02, AMCOM and ARL) FY16-20 TOTAL Plating Shop ~ *AMCOM is also working with ARL to integrate cold spray applications for hard chrome, Cu and Ag plating Remaining open issues to be addressed at a future date: Cadmium sealer (8%) and manganese phosphate (2%) AMCOM G-4 serves as the Program Manager for the aviation portion of the TMR Program Established AMCOM Force 2025 Transition Plan Initiative Projects mostly funded by Army EQT TMR Program with ESTCP and NDCEE projects leveraged 12/15/2016 5

6 Impact of Projects on CCAD Plating Shop with Respect to Cr6 + CCAD Plating Shop Tanks Currently Containing Cr6 + Line Process Num Tanks % Tanks A Black Oxide Seal 1 3 B Manganese Phosphate 1 2 G/T Al Conversion Coat 3 8 H Copper Strip 2 5 L Stainless Steel Passivation 6 15 N-P Chrome Plating Q Magnesium Conversion Coat 5 13 R Cadmium Sealer 3 8 T Chromic Acid Anodize 4 10 T Anodize Strip 2 5 T Hard Coat Anodize Seal 1 3 Total CCAD Plating Shop Tanks Containing Cr6+ if Current Projects are 100% Successful Line Process Num Tanks % Tanks A Black Oxide Seal 1 3 B Manganese Phosphate 1 2 G/T Al Conversion Coat 3 8 H Copper Strip 2 5 L Stainless Steel Passivation 6 15 N-P Chrome Plating Q Magnesium Conversion Coat 5 13 R Cadmium Sealer 3 8 T Chromic Acid Anodize 4 10 T Anodize Strip 2 5 T Hard Coat Anodize Seal 1 3 Total

7 Process Facility Assessments, Design, Contruction (ESPC Phase ID) Tri Chrome Plating (28%) HIGH TECHNOLOGY RISK EQT Laboratory Testing (Faraday Corporation) Demonstration/ LRIP CIP or AMC P2 Complete (Convert 3 Tanks on N Line) Phase II SBIR for Cr6+ Free Stripping Tartaric Sulfuric Acid Anodize (CAA Alternative) (15%) EQT Laboratory Testing (Sikorsky) Demonstration and LRIP ARL Stripping of Anodic Coatings Cyanide Free Copper and Silver Plating (5%) EQT Establish Pilot Process (AMCOM CCAD) Demonstration-Validation Plating-Strike-LRIP ARL Hydrogen Embrittlement and Fatigue Testing Demonstration-Validation Stripping-LRIP ARL Hydrogen Embrittlement and Fatigue Testing ARL Chrome Free Conversion Coatings (Immersion) (8%) EQT Demonstration at CCAD and Outdoor Exposure of BER Parts Update Specification (NAVAIR) and Generate MEOs ARL Tagnite (13%) ESTCP Compatibility Studies, Brush TAG, Stripping, Masking Installation of Tagnite Line & Demonstration Project Full Scale Capability UFR Specification for Tagnite Sealer Non Chromated Sealers (5%) EQT Laboratory Testing Hard Anodize Demonstration-LRIP Laboratory Testing Black Oxide (ARL) Demonstration-LRIP Passivation of Stainless Steel (15%) (NDCEE) Laboratory Testing - Parameter Optimization Demonstration-Validation ARL Cold Spray Plating (Cr) Supplements Trichrome EQT Laboratory Testing Demonstration-Validation ZiNi Replacement for Cadmium Plating (UFR) (8%) EQT RDECOM Cadmium Alternatives IPT Laboratory Testing Demonstration-Validation Maganese Phosphate Sealer (UFR) (3%) TBD Laboratory Testing Demonstration-Validation Laboratory Testing (OffSite) Demonstration at CCAD Requirements Design Construct Assess Power, wastewater, process and equipment needs Figure 1: AMCOM Force 2025 Initiative: Sustainabilty of Plating Shop Processes through the Elimination of of Hexavalent Chromium (as (as of of July 12 14, OCT 2016) 12/15/ LRIP (transition parts via MEOs) CIP or AMC P2 Project Required prior to FRP Evaluation, assessment or other support Completed Task Outdoor Exposure Preliminary Schedule Preliminary Schedule FRP Upgrade via ESPC 1D FRP Upgrade via ESPC 1D Preliminary Schedule FRP Upgrade via ESPC 1D Preliminary Schedule

8 Demonstration and Implementation Strategy Demonstration and implementation planning ongoing Coordination occurring with CCAD leadership Working to stand up a TMR coordinator at CCAD Developing process requirements to assess electrical, chiller, waste water, scrubber requirements etc. TMR funding will facilitate equipment upgrades In three cases this only provides LRIP capability CCAD plans to integrate the TMR requirements into the Energy Savings Performance Contract (ESPC) Phase ID, Plating Shop project Contractor will execute equipment/facility FRP mods Once the demonstrations are complete, Maintenance Engineering Orders (MEOs) will be generated to transition parts to the new process When all parts have transitioned, Cr6+ capability will be taken offline 8

9 Technology Transition Agreement (TTA) Purpose: Ensure all organizations involved in TMR are aware of their roles, responsibilities and commitments Scope: Operational need, project descriptions, development strategy, facility impacts, program schedule, Implementation path, funding, roles and responsibilities and signature pages Signatories: AMCOM G-4, RDECOM, ARL, AMRDEC-AEM, CCAD Deputy Commander, PEO Aviation and AMCOM CoS TTA has been endorsed by all signatories 9

10 Summary AMCOM Force 2025 initiative established to reduce Cr6+ in the Plating Shop by 80% Eight projects are ongoing Established the monthly CCAD Plating Shop Project Working Group Established implementation strategy with CCAD leadership Assessment of facility and equipment requirements for implementation is in work 10

11 Acknowledgement of Funding Organizations 12/15/

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