Air Force Assessment of Materiel Deployed in Southwest Asia

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Air Force Assessment of Materiel Deployed in
Southwest Asia

• Michael W. Surratt
• Senior Corrosion Analyst
• Science Application International Corporation

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Outdoor Storage And Sand Intrusion Not A New
Problem
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Overview

• Project Purpose
• Assessment Methodologies
• AOR Characteristics
• Assessment Observations
• Recommendations
• Conclusions

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Project Purpose

• Reduce the Detrimental Impact of Southwest Asia
  (SWA) Operations on Air Force Equipment.
• Valuable data for
• Weapon Systems Program Managers
• Depot Workload Planners
• Systems Engineers
• MAJCOM System/Functional Managers
• Organizational Maintenance Personnel
• New Acquisitions

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Assessment MethodologyIntroduction

• WR-ALC and AFCPCO Initiated a Study to Evaluate
  and Mitigate Corrosion-Related Problems Expected
  Through Operations in SWA
• Commenced Study Apr 04
• Evaluated Sand From Deployed Locations and Found
  it to Have Much Higher Chloride Concentrations
  Than Any Location Measured to Date
• Potential for Serious Corrosion Problems and TOs
  Need to be Updated to Mitigate the Risks
• The Good News is Most Fixed-Wing Fighter Type
  Aircraft Are in Good Overall Condition with Other
  Platforms Exhibiting Higher Levels of Dust
  Intrusion and Corrosion
• More Affected Helicopters, A-10, C-130, Mobile
  Comm Equipment, AGE, MMHE, Vehicles, Bear Base,
  etc.

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Assessment Methodology Project Objectives
Assess the Physical and Operational Effects of
Extended Ops in the Area of Responsibility (AOR)

• Impact of Corrosion, Erosion, and Dust Intrusion
• AOR Corrosion Prevention and Control Guidance
• Do They Exist and Do They Work?
• Inspection Requirements Field and Depot
  Workloads
• Are the Current Requirements Adequate?
• Corrosion Prevention Compounds (CPCs)
• Effectiveness in Desert Environment?

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Assessment Methodology Project Objectives (Cont)
Assess the Physical and Operational Effects of
Extended Ops in the Area of Responsibility (AOR)

• Effectiveness and Actual Frequency of Wash
  Cycles/Clear Water Rinses
• Water Quality and Availability
• Fixed and/or Mobile Cleaning Capabilities
• Cleaning Equipment, Methods, and Processes
• Alternate Corrosion Prevention and Control
  Methods
• What Works and What Doesnt
• Practical Impact of Alternate Methods on
  Personnel

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Assessment Methodology Team Members

• Warner Robins Air Logistics Center (WR-ALC)
• Rick Johnston - Corrosion Manager
• Air Force Corrosion Prevention and Control Office
  (AFCPCO)
• Dave Ellicks - Materials Engineer
• SMSgt Talmadge Hutchins Team Leader

• Owen Jett Senior Corrosion Analyst
• Program Manager
• Mac McKenna - Senior Corrosion Analyst
• Wes Barfield Chemical Engineer
• Kevin Wilson Senior Corrosion Analyst

• Michael Surratt Senior Corrosion Analyst
• John Bloyer - Materials/Corrosion Engineer
• Joe Yochum Mechanical Engineer
• James Dean - Senior Corrosion Analyst
• John Lindsey - Senior Corrosion Analyst
• Mike Scarry Corrosion Analyst
• Tom Silsbee Corrosion Analyst

• Dr. William Abbott Senior Scientist

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Assessment MethodologySites Visited
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Assessment MethodologyAssessment Plan

• Assembled Subject Matter Expert Team
• First Step -- Identify and Quantify the Extent of
  the Corrosion Problems
• Team Conducted Assessments of Equipment
  In-Country and Recently Returned From SWA
• Interviewed Organizations Maintenance and
  Analysis Personnel
• Queried Available Databases For Anomalies
• Reviewed Pre/Post Deployment Special Inspection
  Workcards or Checklists
• Conducted In-Country Assessments
• Project Final Report Due NLT 31 May 2006

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Assessment MethodologySites Visited
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Assessment MethodologyEquipment Assessed

• Aircraft All Deployed MDS
• Ground and Mission Support Equipment
• Vehicles
• Cargo Loaders
• Munitions
• Munitions Handling Equipment
• Mobile and Fixed Communications Equipment
• Avionics/Electronics
• War Reserve Materiel Repair and Overhaul Locations

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AOR Climatology/Soil Characteristics Evaluated
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USAF Southwest Asia - AOR
www.centcom.mil
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AOR CharacteristicsGlobal Dust Producing Regions
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AOR Characteristics SWA Soil Characteristics
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AOR Characteristics Location, Location, Location
Abu Dhabi
Courtesy NASA - ISD_highres_ISS002_ISS002-354-22
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AOR Characteristics Why Location Is Important
Salt Marsh/Salt Flats
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AOR Characteristics Soil Sample Analysis
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AOR Characteristics Soil Sample Analysis (Cont)
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AOR Characteristics Soil Analysis (Cont)
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Assessment ObservationsProtective Covers

• Protective Covers Can Prevent Water and Dust
  Intrusion
• Protective Covers Can Also Entrap Water Vapor
  Causing Extensive Corrosion On Unprotected Or
  Poorly Protected Metal
• Water Vapor Is Pulled Under the Covers During the
  Warm Days. Water Condenses As Surrounding Air
  Cools
• Covers Need To Be Waterproof But Also Need To
  Breathe Or Have the Equipment Otherwise
  Protected, CPCs, Lube, Etc.

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Assessment ObservationsSand and Humidity
Intrusion

• Top Photo
• Sand Accumulation Inside A Missile Shipping
  Container Note Clumping of the Sand Indicate
  Humidity was Present at One Time Developing
  Mineral Cementation Caused by the Evaporite
  Minerals
• Center Photo
• Sand Accumulation Inside a C-130 Nose Landing
  Gear Well Undergoing Depot Depaint and Repaint
  Hard Crust Noted 5/8-Inch Thick
• Bottom Photo
• Thickness of Sand Crust Taken From the C-130

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Assessment ObservationsCorrosion

• Findings
• Some SWA Soils Include Salts
• Condensation Dissolves and Concentrates Salts
• Accelerated Corrosion Anticipated from Resultant
  Electrolytes

• Lack of Effective In-Country Cleaning
  Capabilities and Resources
• Specifically for Permanently Stationed Equipment
  (Vehicles, AGE, etc.)
• Poor Water Quality Likely to Promote Corrosion
  Versus Prevent It

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RecommendationsWash Cycles and Cleaning

• While Washing is an Effective Corrosion
  Prevention Method, the Current SWA Environment
  Presents a Unique Challenge
• AFCPCO/Battelle/SAIC Opinion
• The Risks Of Washing Temporarily Deployed
  Aircraft Outweigh The Benefits
• Permanently Assigned Equipment Should Be
  Regularly And Thoroughly Cleaned
• At The Request Of HQ ACC/A4 Two Potentially
  Deployable Wash Systems With Recycling Capability
  for Permanently-Stationed Equipment Evaluated

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RecommendationsTransportable/Deployable Wash
System

• Two Wash Systems Evaluated
• Concluded a Hybrid System Was Best Candidate
• Containment Structure is a Modular Building With
  an Air Handling System
• Containerized - Envision three - Twenty Foot ISO
  Containers
• Takes a 4-person Crew 20 Hours to Set Up (One
  Forklift and Two-man Lifts)
• Sufficient Capacity to Cleaning of Support
  Equipment, Vehicles - Up to Large Cargo Loaders

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Recommendations Near-Term Vehicle And Support
Equipment

• Develop Infrastructure to Support In-Country
  Vehicle/Support Equipment CPC Program
• Identify, Validate, and Procure Effective
  Cleaning Systems
• Establish a Program of Frequent Sand/Dust
  Removal, Washing, Rigorous Touchup Program, and
  Use of CPCs
• Study the Use of SWA WRM Locations for In-Country
  Support Equipment Refurbishment Modify Existing
  Gov Contract at WRM Locations
• One-For-One Equipment Changeout

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RecommendationsGeneral

• Develop Weapon System-Specific Guidance for
  Desert Ops and Pre- and Post-Deployment Actions
  (MeSDEP - abbreviated Army RESET)
• SPO Develops Approves with CPAB Input
• MAJCOM Approves Implementation Resource Needs
• Where Possible Utilize Hard Film CPCs for Bare
  Metal Touchup
• Inspect/Clean Electrical Components/Filters
  Regularly
• Shelter Aircraft/Equipment to the Greatest Extent
  Possible
• Potential for 4-10X Reduced Rate of Corrosion
• Use Properly Positioned AFCPCO/Battelle Developed
  Sensors To Help Quantify Potential Corrosion
  Risks Resulting From Unique Environments
  (Condition-Based Maintenance) Begin Positioning
  Sensors in Corrosion Prone Locations on
  Ground-Based Equipment

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RecommendationsNear-Term AFCPCO

• Update General Desert Operations/Reconstitution
  Guidelines to Our General Series TOs
• Effective Dry-Cleaning Equipment to Remove Dust
• Wash Instructions for Permanently-Stationed Eqpt
• Use of CPCs (Application, Reapplication, Types,
  etc.)
• POC AFRL/MLS-OLR (AFCPCO)
• Timeline Draft by Mar 06, Pub Jun 06
• Work with Weapon System Managers To Implement
  Similar Guidance Specific To Their Systems (In
  Applicable -23 TOs -6 WCs)
• POC Weapon System Mgrs, AFCPCO
• Timeline Over next year through CPABs

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Recommendations Long-Term

• Insert Training Needs into Applicable UTWs
• POC AFRL/MLS-OLR, HQ USAF/ILMM, MAJCOM
  Functionals
• Timeline Recurring
• Integrate Effective Corrosion Prevention Into
  Product Design
• DFARS requires Contracts gt5M have Corrosion
  Prevention and Mitigation in Acquisition Plans
• POC AFRL/MLS-OLR, SAF/AQ, PMs/CPABs
• Timeline Recurring

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Recommendations Near-Term General

• Inbound/Outbound Equipment Awaiting Shipment at
  TMO in Open Storage Areas Contained Significant
  Amounts of Dust Upon Arrival at Home Station
• Recommend Storage in Temporary Shelters,
  Immediate Cleanup Upon Arrival at Home Station
• Unable to Accomplish Engine Compressor Washes on
  C-130s and MH-53 Due to Hazardous Waste
  Associated to Heavy Metal Levels of Wash Water
• Recommend Closed Loop Wash System to capture
  Effluent and Isolate Waste
• OEM Applied Powder Coatings are not Withstanding
  the Rigors of SWA -- Cause Coating
  Thickness/Surface Prep
• Ensure Only Proper Powder Coating Selection with
  Sufficient Thickness be Applied Over Properly
  Prepared Surfaces

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Recommendations Near-Term General (Cont)

• Under-panel Dust Intrusion Due Mostly to
  Ineffective/nonexistent Sealants or Seals
• Recommend Evaluation of Gel-type Seals be Used to
  Prevent Dust and Fluid Intrusion
• Standing Water Noted in Many Recessed Areas of
  Equipment
• Recommend ensuring all equipment has
  drain-through/drain-to locations and existing
  holes free of debris and standing water
• Sand and Dust Accumulation in Wheel Wells
• Regardless of Deployed Location, Recommend
  Removal of All Sand and Dust Accumulation

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Recommendations Near-Term General (Cont)

• Contamination of the Lubricants with Sand/dust
  Impairs Mechanical Operations of Aircraft and
  Exterior Missile Guidance Components
• Recommend Identifying Lubricants That Can Be
  Effectively Used in Desert or Dusty Environments
• Numerous Electrical Connectors Interiors are
  Prone to Dust Intrusion and Corrosion
• Evaluate the Use of Proven Avionics Grade CPCs on
  Connector Pins and Cold Shrink Rubber
  Boots/tubing on Exterior Back Shells to Prevent
  Water and Dust Intrusion, Gel-type Gaskets, and
  Potting Compounds

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Conclusion

• Team Did Not Find Hard Data to Support
  Significant Aircraft Corrosion Was Directly
  Attributable to SWA Operations
• Data Supports There is a Significant Corrosion
  Risk After Return To Home Station if Effective
  Reconstitution Program Is Not Effectively
  In-Place
• Team Did Find Significant Corrosion Problems With
  Permanently Deployed Equipment
• Recommend Establishing a Program Washing, Along
  with Rigorous Touchup Program and Use of CPCs
• Use of SWA WRM Locations for In-Country Support
  Equipment Refurbishment
• Pre Post Deployment Actions are Vital to
  Preventing Corrosion in the Future
• Consolidated Intermediate Repair Facility (CIRF),
  Depot Agile Repair Team, Costly but Essential
• Maximize CPAB Effectivity

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Points of Contact

• Air Force Corrosion Prevention And Control Office
  Mr. David Ellicks, [phone], (DSN Prefix
  468) Email david.ellicks_at_robins.af.mil
• Warner Robins ALC /ENFM Mr. Frederick Johnston,
• [phone], (DSN Prefix 468) Email
  rick.johnston_at_robins.af.mil
• SK Technologies Mr. Owen Jett
• [phone] , (DSN Prefix 468) Email
  owen.jett_at_robins.af.mil
• Science Applications International Corp - Mr.
  Michael Surratt
• [phone] Email surrattm_at_saic.com

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• QUESTIONS?