Atmospheric Plasma Depainting. Peter Yancey Atmospheric Plasma Solutions, Inc.
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1 Atmospheric Plasma Depainting Peter Yancey Atmospheric Plasma Solutions, Inc.
2 Report Documentation Page Form Approved OMB No Public reporting burden for the collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden, to Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington VA Respondents should be aware that notwithstanding any other provision of law, no person shall be subject to a penalty for failing to comply with a collection of information if it does not display a currently valid OMB control number. 1. REPORT DATE 19 NOV TITLE AND SUBTITLE Atmospheric Plasma Depainting 2. REPORT TYPE 3. DATES COVERED to a. CONTRACT NUMBER 5b. GRANT NUMBER 5c. PROGRAM ELEMENT NUMBER 6. AUTHOR(S) 5d. PROJECT NUMBER 5e. TASK NUMBER 5f. WORK UNIT NUMBER 7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) Atmospheric Plasma Solutions, Inc,11301 Penny Road??? Suite D,Cary,NC, PERFORMING ORGANIZATION REPORT NUMBER 9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSOR/MONITOR S ACRONYM(S) 12. DISTRIBUTION/AVAILABILITY STATEMENT Approved for public release; distribution unlimited 11. SPONSOR/MONITOR S REPORT NUMBER(S) 13. SUPPLEMENTARY NOTES ASETSDefense 2014: Sustainable Surface Engineering for Aerospace and Defense, Nov 2014, Fort Myer, VA. 14. ABSTRACT 15. SUBJECT TERMS 16. SECURITY CLASSIFICATION OF: 17. LIMITATION OF ABSTRACT a. REPORT unclassified b. ABSTRACT unclassified c. THIS PAGE unclassified Same as Report (SAR) 18. NUMBER OF PAGES 33 19a. NAME OF RESPONSIBLE PERSON Standard Form 298 (Rev. 8-98) Prescribed by ANSI Std Z39-18
3 Outline Problem Statement Define Plasma Define Atmospheric Plasma Describe Atmospheric Plasma Coating Removal (APCR) Benefits of APCR Introduce the PlasmaFlux TM APCR system Aerospace Depainting Efforts Navy Ship Depainting Efforts 2 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
4 Problem Statement Annual cost of corrosion for DoD ~ $22 Billion Virtually every weapon system across all segments of DoD require periodic maintenance of coating systems Plastic Media Blasting High Pressure Water Jet Grit blasting 3 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
5 Problem Statement Conventional paint and coating removal techniques are based on a variety of mechanical or wet chemical techniques. Media based (sand/grit, dry Ice, and plastic media blasting) High pressure water Liquid Solvent Chemical stripping Disadvantages Labor intensive High materials cost (procurement, storage, transport, disposal) High environmental cost (solid / liquid waste disposal) Potentially damaging to some substrate materials (composites) 4 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
6 Solution: Atmospheric Plasma Coating Removal 5 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
7 What is Plasma? 6 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
8 Increasing Energy Plasma: Fourth State of Matter Plasma Gas Solid Liquid State of Matter 7 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
9 What is Atmospheric Plasma? 8 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
10 What is Atmospheric Plasma? Plasma occurring at Atmospheric Pressure Plasma with Atmospheric Composition (Compressed air is only gas required) 9 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
11 Atmospheric Plasma Coating Removal (APCR) + = Atmospheric Plasma Paint / Sealant Carbon Dioxide Water Vapor APCR requires no media Atmospheric plasma produces highly reactive gas Cold plasma high chemical energy, low thermal energy Vaporizes organic portion of coatings to CO 2 and H 2 O No damage to temperature sensitive substrates 10 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
12 Features and Benefits of APCR Technology Feature No Media Required Atmospheric Pressure Operation Benefit Cost - Reduced procurement, storage, and disposal costs Safety - Reduced exposure to hazardous materials Environmental Reduced environmental impact Non-damaging removal, preserves surface profile Selective layer-by-layer removal Consumables: Compressed Air and Electricity Safety No special safety equipment or procedures Cost Eliminates need for hot work zones, faster maintenance cycle Compact size, low weight Controlled manually or by robotics Reaches areas that are inaccessible to other technologies 11 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
13 PlasmaFlux APCR Technology Power Supply Plasma Source The power supply produces a high frequency electric field to generate cold plasma Depot compatibility: Requires only compressed air and electrical power 12 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
14 Aerospace Depainting Efforts APC (Advanced Performance Coating), RAM (Radar Absorbing Material), and Sealant removal Aluminum, Titanium, Composite substrates Accessing confined spaces where other technologies struggle 13 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
15 Aerospace Depainting Efforts APC on Aluminum Removal to Primer RAM on Carbon Fiber Partial Topcoat Removal APC Topcoat RAM Treated Area 14 Atmospheric Plasma Depainting, ASETSDefense, Nov 19,
16 Aerospace Depainting Efforts Selective layer-by-layer removal has been demonstrated on contoured substrates using 3-axis automated systems 15 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
17 Hand Held Removal of Polysulfide Sealant AC-240-B2 Sealant (2-5 mm thick) applied to lap joint with protruding rivets ~15 second handheld removal around rivet leaving bare metal and powdery residue 16 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
18 Primer Removal, Sealant Removal C-130 Aluminum Wing Corner Fitting Controlled RAM Removal to primer 17 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
19 Primer Removal, Sealant Removal C-130 Aluminum Wing Corner Fitting 18 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
20 Aerospace Coating Removal Transition Programs AFRL (WPAFB) Evaluation of high power atmospheric plasma process for aircraft coating removal Evaluation of handheld APCR for Sealant removal NAVAIR (Cherry Point) Evaluate AP for weld surface prep on Nickel Superalloys Ongoing projects with prime contractors Evaluating APCR for surface treatment of aircraft fasteners and sealant removal Evaluating removal of specialty LO coatings on composite substrates 19 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
21 Naval Depainting Development Programs Navy Phase I & II SBIR (N C-0266) Projects focused on engineering development challenges Modular 20kW, Stackable Power supplies Improved single and multi-pen designs Ruggedization for Dry-dock environment Operation using Dry-dock 480V 3-phase power 20 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
22 Naval Depainting Development Programs SERDP WP-1762 (NCSU Lead, APS Co-performer) Recoating performance of APCR depainted surfaces Multi-pen removal process development using SBIR designed plasma system Removal rate enhancement on Naval ship coatings Plasma plume-surface interaction Environment, Safety and Occupational Health characterization of the plasma depaint process 21 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
23 Naval Coatings Removal Plasma pen integrates with COTS automated system for coating removal tests Sample coupons 24 x 36 3/8 DH36 steel (± 2.5 mil roughness) Coating stacks Freeboard Anti-Fouling 20 mils thick (nominal) Three axis automated system 22 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
24 Anti-Fouling Coating Removal APCR produces surface with near white metal blast cleanliness Underlying surface profile is unchanged Uniform removal demonstrated for freeboard and anti-fouling coatings Demonstrated excellent adhesion of re-applied coating with no secondary wiping or cleaning required to recoat 23 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
25 APCR Multi-Pen Array Eight Pen Array 24 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
26 SERDP Program Findings Comparable efficacy of APCR to conventional Naval coating removal techniques Test panels were depainted by grit blasting and APCR to near white metal conditions and then repainted No significant performance difference of reapplied coatings was observed between APCR and grit blast surface preparation No discernible difference in surface grain size, structure, or composition. Pull-off adhesion tests of re-applied coating are comparable No significant coating performance difference in salt fog and cathodic disbondment testing 25 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
27 Solid Mass Reduction Study Determine what % of coating is converted to vapor Closed system employed during coating removal to capture solid waste Results indicate that up to 60% of coating mass was converted to gaseous byproducts EDS analysis of solid residue showed primarily inorganic content Freeboard Silicone Alkyd, PRF % reduction Antifouling, 60% reduction 26 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
28 Technology Transition Scale up plasma coating removal technology to increase production rates Increased power levels (power source and plasma pen) Multiple Plasma Pens Wide Area Plasma Source Ruggedize power supply and pen for testing under depot conditions Outdoor marine environment: Category III, Pollution Degree 4 Compliance standards taken into consideration in design 27 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
29 Technology Transition Seeking Strategic Partnerships to further develop APCR technology for specific applications, demonstration and evaluation 28 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
30 Acknowledgements: Jeff Kingsley, WPAFB Natasha Voevodin, WPAFB Steve McElvany, ONR Bill Hertel, NSWC Carderock Darren Melhuish, NSWC Carderock Jerry Cuomo, NCSU Steve Hudak, NCSU Robert Kestler, NAVAIR- Cherry Point Bruce Sartwell, SERDP/ESTCP Robin Nissan, SERDP/ESTCP 29 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
31 Support Provided, in part, by the following U.S. Gov. contracts: FA M-5606 N M-0161 FA C-5607 FA D-5600/0005 N C-0322 FA D-5610/0011 SERDP WP Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
32 Thank You, Questions? Contact Information: Peter Yancey 31 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
33 32 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
34 Complete Integration of AP coating removal with High Performance Robotics Facility Compressed Air, 90 psi Plasma Flux Power Supply COTS Six-Axis Robot 240 VAC Single Phase 60Hz VENT To Facility HEPA <= Filtration Aircraft part Particulate Collection System 33 Atmospheric Plasma Depainting, ASETSDefense, Nov 19, 2014
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