Aging Aircraft Branch Overview. AMTC Steve Smith
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1 Aging Aircraft Branch Overview AMTC Steve Smith
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 FEB TITLE AND SUBTITLE Aging Aircraft Branch Overview 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) U.S. Coast Guard,Aging Aircraft Branch,Elizabeth City,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 13. SUPPLEMENTARY NOTES 2009 U.S. Army Corrosion Summit, 3-5 Feb, Clearwater Beach, FL 14. ABSTRACT 11. SPONSOR/MONITOR S REPORT NUMBER(S) 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 28 19a. NAME OF RESPONSIBLE PERSON Standard Form 298 (Rev. 8-98) Prescribed by ANSI Std Z39-18
3 Corrosion Cell/AAB Working specifically on supporting programs like sheltering, dehumidification and other corrosion prevention methods. Leveraging DoD and industry on joint initiatives to mitigate corrosion Coordinate with CG Headquarters and Aviation Facility Manager to support initiatives which improve mission readiness and reduce life cycle costs Among the challenges the services face in keeping their equipment and supplies in good operating condition is corrosion caused by exposure to the environment. GAO
4 Coast Guard Corrosion Program Goals Where the Rubber Meets the Road Identify and Implement Real Time Corrosion Mitigation Initiatives. Introduce State-of-the Art Technology. Institute a Continuing Comprehensive Corrosion Training Program. Establish an Extensive Corrosion Mapping Program. Cultivate an Aggressive Corrosion Preventative Advocate Program. Construct Environmental Severity Indices. Implement a Dehumidification Program. Drive PDM and MPC Schedules.
5 U.S. Coast Guard Aircraft Total Aircraft: 199 Total Air Stations: 27 (Including HITRON & APO) HH60 41 Aircraft 8 Air Stations HU25 23 Aircraft 5 Air Stations HH65 99 Aircraft 17 Air Stations HC144 3 Aircraft (5 additional on order) 1 Air Station HC Aircraft (incl. 6 J models) 5 Air Stations
6 Corrosion in Coast Guard Aviation Age of Aircraft Environmental Severity Operational Demands Remote Deployments Hanger Deck Experience Level Rescue Swimmer Ops New Deepwater/Homeland Security Challenges
7 Corrosion Prevention Advocate Drives the Air Station Corrosion Program Ownership Prime Duty Billet (E7/E6) Water Testing Provide Training Approved Chemical List Station TIMI / Eng Instruction Report Directly to Engineering Officer
8 Logistics Compliance Inspections Ensure Your House is in Order Evaluate Effectiveness of Corrosion Control Program CPA Involvement Engineering Instruction Adherence to Process Guide Aircraft Inspections
9 Water Analysis Tested Semi-Annually by CPA Aircraft Computerized Maintenance System (ACMS) Dissolved Solvents < 500 ppm Chlorides < 50 ppm ph: 6 8 HH65C Turbomeca requirements MPC GS
10 C-130 Wash: 2 Weeks (Flap/Wheel Wells) Wash: Monthly (Fuselage HU-25 Wash: Weekly Rinse: Daily (Engines) HH-60 Wash: Daily & 14 Day Detail Inspection Rinse: 50 Salt Water Hover HH-65 Wash: After last flight of day/post Flight Rinse: Flights below 500 feet Wash: For 7, 14, 30 inspections Aircraft Cleaning Most Effective Tool in Preventing Corrosion Required: Hot Water ( Degrees) & Foamers
11 Corrosion Prevention Compounds C-130 ACF-50: Fogging airframe application /Amalguard HH60 / HH65 Fluid Film - Fogging w/ Liquid A HU-25 Mil-PRF Type 1 - Fogging New Revision MIL-PRF Mil-PRF-85054
12 Corrosion Training Aircraft Corrosion Control - Pensacola FL. (Air Force) Course Code # (Resident and Exportable) Advanced Composite Technology - Sparks, NV Course Code # (Resident and Exportable) Aging Aircraft Corrosion Control (Fills requirement for Corrosion Process Guide) Annual CPA Seminar (Sandia Natl. Labs) Now includes training for Student Engineering Officers
13 Sheltering & Dehumidification GAO Report Reports to Congressional Committees June 2006 Higher rates of corrosion result in increased repairs and replacements, drive up costs, and take critical systems out of action, reducing mission readiness. Corrosion can also reduce the safety of equipment items. Although reliable cost data are not available, estimates of corrosion costs DOD-wide have ranged from $10 billion to $20 billion annually. 3 Month Study Elizabeth City Ambient H60 Hangar DRS Climate Controlled Hangar One Army study showed that sheltering equipment in a humiditycontrolled facility had a return on investment, at minimum, of $8 for every $1 invested.
14 Battelle Corrosion Severity Test Results 3 Month Outdoor Exposure E-City Air Station 12 Month Indoor Exposure E-City HH-60 Hanger 12 Month Indoor Exposure HMF Environmentally Controlled
15 Corrosion Mapping Physical Airframe inspections Target Specific Grid/Zones Currently Depot Only Light 7,684 Moderate 1,988 Severe 3,840 Other 2,746 Total 16,258 ACMS - ALMIS Data Base Pictorial & Data Views
16 Dehumidification Program Bringin Arizona to the Air Stations ARIZONA USCG Air Stations Maintaining low humidity levels reduces corrosion because moisture is a primary cause of corrosion. GAO
17 DH & Corrosion Rates/Avionic Benefits Why use Dehumidification? Reduction in Relative Humidity (moisture). A dry airframe is a happy airframe. Corrosion increases at RH levels above 60%. Below 45% RH, corrosion process virtually ceases. (Source: Naval Audit Service ) MTBF greatly reduced with humidity levels below 50% Relative weight loss Rate of corrosion 1 CG Units average annual humidity range Cape Cod Corrosion STOPS Houston % Relative Humidity Relative Rate Operational A/C Electronic Failures 2 Controlled Humidity Protection Relative Humidity (%) 1 Vernon, W. H. J. (1926). 2 Sandia National Laboratories
18 Site assessments complete at all CG Prime Units. Requirements: Ease of use On /off in 5 minutes Lower relative humidity in 1 hour to at or below 40% RH Hangar / ramp operations Temperature / Relative Humidity C130/HH60 Elizabeth City, NC HH65 Atlantic City, NJ HU25 Mobile Alabama Units have been delivered to all Prime Units, OT&E underway. Dehumidification Efforts Note: One Army study showed that sheltering equipment in a humidity-controlled facility had a return on investment, at minimum, of $8 for every $1 invested.
19 Dehumidification Increases Readiness & Availability 20% increase in aircraft availability. 24% decrease in no fault found discrepancies. 15% decrease in unit level maintenance of avionics* * Source: United Kingdom testing on the Tornado aircraft. Higher rates of corrosion result in increased repairs and replacements, drive up costs, and take critical systems out of action, reducing mission readiness. GAO
20 Exceeding 8 hrs/day DH Metrics Increased Reliability Fiscal Years 1Q01 2Q01 3Q01 4Q01 1Q02 2Q02 3Q02 4Q02 1Q03 2Q03 3Q03 4Q03 1Q04 2Q04 3Q04 4Q04 1Q05 Milestones: DH Employment Limited More Full? 1st DH Cart 2nd DH 3rd DH Rec'd. Cart Rec'd. Cart Rec'd. 1 DH Cart Down Seperators: Replace Socks, Check/Clear 14-day Replace 30-day Aircraft W/AP Problems Close/Hangar Aircraft Water intervals intervals Replacement Aircraft: Avionics* Reliability (Failures/1,000 Hours): Data that could help reduce corrosion of pre-positioned assets are not available. They are not available because the services consider this information to be a low priority and do not systematically collect it. GAO * Avionics composite average of APC-80M, APA-80M, 618M-3A, SCC-807, ADC-80, and SCD
21 New DH Carts from
22 Wiring Corrosion Prevention Use CPCs like MIL-C to prevent cannon plug corrosion. Develop a training program for aircraft aging wiring. Implemented the use of Avdec SLG to prevent cannon plug corrosion. Implemented the use of Avdec antenna gaskets to prevent corrosion.
23 Vibration Lab (Technical Capabilities) Helitune Field Support Real-Time Dynamic Data Acquisition and Analysis Historical Data Archive & Trending Model Testing Commanding Officer US Coast Guard ARSC Engineering Vibration Lab Hwy 34, Bldg 100 Elizabeth City, NC Attn: AMTC Ramirez or Jim Cowgill Phone No /6835
24 USCG Nondestructive Inspection Tools used to detect metallic and non-metallic defects and evaluate / monitor for limitations after repairs Bond master style instrument to determine Unbond, debonding and disbonding in composite materials. Rusty Waldrop USCG NDI Program Manager Rusty.G.Waldrop@USCG.MIL Thermal Imaging acquisition system Currently being reviewed for depot level Maintenance Radiography Currently in use at ARSC Ultrasonic Method currently being trained To detect corrosion and measure material thicknesses Staveley Eddy current machines, Currently being used in the fleet..
25 Partnership Industry Sister Services Ongoing relationship with Joint Council of Aging Aircraft (JCAA) provides unique opportunities through Corrosion Steering Group (CSG) Funding for HH60 AvDec gaskets Funding for magnesium coating evaluation Interaction with Office Secretary Defense (OSD) Guidance through a focused corrosion Team effort Army/Air Force Corrosion Office / NAVAIR
26 Control or Prevention
27 Control or Prevention
28 No Magic Bullet Basic Maintenance Practices Ownership / Buy In Attention to detail Pride in your efforts
29 Questions? CWO Erick Ludwigson Corrosion Program Manager PH: (252) AMTC Steve Smith Asst. Corrosion Program Manager PH: (252) Website: FAX: (252) Mr. Bryant Denning Rotary Wing Corrosion Prevention Advocate PH: (252) Mr. Jim Valky Fixed Wing Corrosion Prevention Advocate PH: (252)
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