C-5 Corrosion Prevention Compound (CPC) Application/Evaluation Program

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C-5 Corrosion Prevention Compound (CPC)
Application/Evaluation Program
U.S. Air Force Presentation
March 2006

• Dan McTish / Scott Jones
• Lockheed Martin Aeronautics Company
• 770-494-4489
• dan.j.mctish_at_lmco.com
• scott.a.jones_at_lmco.com

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Introduction

• This work is being performed under an OSD
  initiative to fund corrosion prevention and
  control projects that would provide rapid,
  measurable, corrosion benefit to weapon systems.
• WR-ALC received matching funds for conducting a
  field trial of proven corrosion prevention
  compounds (CPC) on operational aircraft.
• WR-ALC Program Manager
• Mr. Buc McRory
• DSN 468-6663
• Comm 478-926-6663

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C-5 CPC Team

• Team composed of technical experts from all
  associated fields.
• WR-ALC (Buc McRory)
• Battelle (Bill Abbott, Ernie Patterson)
• USAF Corrosion Office (Dick Kinzie)
• ANG Corrosion Office (Jerry Powell)
• HQ/AFRC (Mark McIntosh)
• 439 AW / Westover ARB (MSgt Robert Ivey)
• 433 AW / Lackland AFB (MSgt Nick Peche)
• 105AW / Stewart ANG (MSgt Larry Keeno, TSgt Stan
  Hyla)
• 445AW / Wright Patterson AFB (TSgt Scott McCoy)
• SKT (Jill Ullett, Charlie Gibbs)
• USAFA (LtCol Scott Fawaz)
• University of Virginia (Rob Kelly)

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C-5 Fleet
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Contract

• CPCs Were Applied To Corrosion-Prone Areas On 6
  C-5A Aircraft In May 2005.
• CPCs Were Not Applied Over Corrosion.
• Aircraft Were Provided From Westover ARB, Stewart
  ANG and Lackland AFB.
• CPC Performance Being Monitored For A Period Of
  24 Months (February 2007).
• Copper sensors (unobtrusive) from Battelle were
  installed in all areas.
• Steel sensors (short life) were only installed in
  wet areas.
• Coated and Uncoated Sensors were installed in
  each area.
• Sensor Data Downloads and Visual Inspections
  being performed at 120 day intervals.
• Data to be used to determine
• Effectiveness
• Dirt Accumulation
• Reapplication Intervals
• CPC Touch-up No Longer Being Performed. Need to
  Determine Service Life.

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CPC SELECTIONTypes of CPC

• Thin Film (D-5026NS, AV-25, LPS2)
• Displace water and penetrate voids in faying
  surfaces, cracks, and around fastener heads.
• Less effective in areas of high water runoff when
  compared to waxy or hard film compounds.
• Waxy (Not Used)
• Non-water displacing or barrier type compounds.
• Do not penetrate faying surfaces very well.
• Dirt accumulation a problem.
• Hard Film (Cor-Ban35, AV-15, Procyon)
• Penetrating, water-displacement capabilities
  along with barrier type performance with one
  product.
• Penetrate voids, cracks, or faying surfaces and
  displace moisture.
• Cures to a very firm, non-tacky, barrier type
  film.

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CPC SELECTIONConsiderations

• All CPC are considered temporary when compared to
  the more durable paint type finishes like epoxy
  primer and polyurethane topcoats.
• Periodic reapplication and/or touch-up will be
  required for CPC to remain effective.
• Visual inspections will be primary CPC evaluation
  method.
• Sensor Data will be used to evaluate CPCs and to
  determine if reapplications are beneficial.
• Up to 64 Sensors Installed on Each C-5 Aircraft.
• Reapplication intervals expected to be anywhere
  from 1 year to several years.
• CPCs can be utilized on C-5 aircraft as an
  inexpensive approach (over paint) to provide
  additional corrosion protection in bilge and
  empennage.

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CPC SELECTIONDecision Process

• Data used to select CPC for each treatment area
• Corrosion Type
• SCC, exfoliation, paint degradation, fluid
  entrapment, condensation, or a combination
• Environmental Influences
• 120 Day Wash Cycle in wheel well, chine, tiedown
  pans
• Existing fluids in faying surfaces - bilge
• Excessive Heat on Upper Lobe Skins (160F)
• Reapplication Requirements
• Material (ferrous/non-ferrous)
• Existing Finish

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C-5 CPC TREATMENT AREASSELECTION PROCESS

• Data used to select corrosion prone areas
• User Conferences (CPAB, ASIP, FSIP, PIWG)
• Corrosion Manual (T.O. 1C-5A-23)
• Discrepancy Forms (AFTO 107, AFTO 202, AFTO 95)
• Discrepancy Databases (FODATS, STFS)
• Open Communication (Telecom, Email)
• Candidate treatment areas were finalized based
  upon the following requirements
• Accessibility (Base level)
• Varying environmental conditions
• Data applicable to multiple areas

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(No Transcript)
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NLG Wheel Well Aft Bulkhead (FS 664) LHS
OnlyCor-Ban 35, AV-15, Procyon
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NLG Wheel Well Aft Bulkhead (FS 664) LHS
OnlyCor-Ban 35, AV-15, Procyon
69-0027
Nicks From NLG Wheel Spin Debris Aerosol Touch-up
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MLG Mainframes (FS1303/1383/1523/1603) LHS
OnlyCor-Ban 35, AV-15, Procyon
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MLG Aft Bulkhead (FS1638) LHS OnlyCor-Ban 35,
AV-15, Procyon
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MLG Aft Bulkhead (FS1638) LHS OnlyCor-Ban 35,
AV-15, Procyon
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Keel Beam Vertical Panel LHS OnlyCor-Ban 35,
AV-15, Procyon
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Keel Beam Horizontal Shelf LHS OnlyCor-Ban 35,
AV-15, Procyon
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Keel Beam Horizontal Shelf Steel
SensorsCor-Ban 35, AV-15, Procyon
After 150 days on 68-0212
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Forward Ramp Cargo Tiedown ReceptaclesCor-Ban
35, AV-15
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Forward Ramp Cargo Tiedown ReceptaclesCor-Ban
35, AV-15
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Chine Cove from FS1884 thru FS1964 RHS
OnlyCor-Ban 35, AV-15, Procyon
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Floor Panel Behind Troop Latrine RHS
OnlyCor-Ban 35, AV-15, Procyon
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Fuselage Belly Skins from FS1064 to FS1106 RHS
OnlyD-5026NS, AV-25, LPS-2
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Bulkhead End Fittings at FS1064 FS1106 RHS
OnlyD-5026NS, AV-25, LPS-2
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Intermediate End Fittings at FS1084 FS1128
RHS OnlyD-5026NS, AV-25, LPS-2
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Crew Lavatory Ground Service Pan - RHS
OnlyCor-Ban 35, AV-15, Procyon
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Crew Lavatory Ground Service Pan - RHS
OnlyCor-Ban 35, AV-15, Procyon
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Crew Lavatory Ground Service Pan - RHS
OnlyD-5026NS, AV-25, LPS-2
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Crew Lavatory Ground Service Pan - RHS
OnlyD-5026NS, AV-25, LPS-2
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Pressurized Upper Lobe Skin, Frames Stringers
D-5026NS, AV-25, LPS-2
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UnPressurized Upper Lobe Skin, Frames
Stringers D-5026NS, AV-25, LPS-2
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UnPressurized Upper Lobe Skin, Frames
Stringers D-5026NS, AV-25, LPS-2
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C-5 CPC TREATMENT AREASCPC Selection
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Total Flight Hours (Cumulative)
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Sensor Data 120 days
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Program Status Hard Film CPC

• Hard films applied using both HVLP equipment and
  aerosol cans.
• Hard film CPC (CorBan35, AV-15) performing well,
  with only minor touch-ups to nicks behind gear.
  (Touch-ups no longer being performed)
• Procyon not surviving operational environment.
• Dyed (salmon, brown) hard film use over white
  paint in wheel wells resulted in negative
  feedback. White wheel wells easier to keep
  clean.
• Undyed CorBan 35 and Undyed AV-15 applied with
  much better feedback from base personnel.
• CorBan 35 and AV-15 application results over
  cadmium depleted fasteners in cargo tiedown pans
  still inconclusive. (UV issues)

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CorBan 35 Dyed vs. Undyed
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AV 15 Dyed vs. Undyed
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Program Status Thin/Oily Film CPC

• Thin films applied using aerosol cans.
• Confined bilge area applications attempted with
  HVLP equipment, but aerosol cans provided much
  better mobility.
• Bio-Environmental tested air during aerosol bilge
  applications. Full face respirators were
  recommended but half-face were sufficient.
• Thin oily films in upper lobe providing
  protection, but excessive heat (160F) is causing
  some CPCs to evaporate after only 120 days on
  exposed surfaces. Benefits may still be realized
  over time.
• Reapplications performed in upper lobe at 120
  days on 3 aircraft to determine if reoccurring
  applications are necessary.
• Thin oily films in bilge remaining oily to touch
  after 8 months and three wash cycles.
• Minimal dirt accumulation in bilge after 8
  months.

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Thin/Oily Film CPC Dirt Accumulation
After 8 Months on Flight Line Fence
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Current Program Issues

• Coat additional areas with thin film CPCs on
  bilge skins and upper lobe skins to obtain more
  performance data.
• Determine from sensor readings and visual
  inspections if continual reapplications of thin
  film CPCs in HOT upper lobe are necessary.
• Continue to monitor thin film CPCs for dirt
  accumulation.
• Verify Undyed hard film CPC is preferred over
  white paint in wheel wells.
• Determine if CPC products will be listed by
  product name or by specification in tech orders.
• Ground test CorBan 22 self-healing soft film for
  possible use on Horizontal Pivot Shafts.
• Propose that CPCs and sensors not be removed
  from aircraft in February 2007 and that bi-annual
  performance evaluations be performed.

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C-5 CPC Application/Evaluation Field Team
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CLOSING REMARKS / ADJOURN

• QUESTIONS
• COMMENTS