Registration is closed for the Workshop on Sustainable Surface Engineering for Aerospace and Defense, which was held at the Rancho Bernardo Inn, San Diego, California, August 27-30, 2012, with a side meeting on Cd alternatives for electrical and optical connectors on the afternoon of August 27. This workshop was our fourth to date on sustainable surface engineering technologies.
Since our workshop in February 2011 there had been significant tightening of regulations affecting chromates and other coating materials.
- Recent changes in the OSHA rules for minimizing hexavalent chromium exposure in the workplace are creating significant costs and complications at military depots.
- New EPA Cr6+ air emissions regulations proposed for early 2012 will decrease the allowable Cr6+ emissions from hard chrome plating, anodizing, chromate conversion and sealing, while at the same time EPA rules will be eliminating the PFOS fume suppressants that allow many platers to meet the current standards.
- The hexavalent chromium minimization DFARS have come into effect, requiring authorization to use chromated primers and other coatings in new military contracts.
- The European REACH rules are rapidly expanding the number of surface treatment chemicals that cannot be used in Europe without Authorization. This could have serious consequences for sales and sustainment of weapons systems in Europe, especially since chromic acid and most chromates are among the first chemicals to require Authorization.
- The European RoHS law has been broadened to restrict Pb, Cd and Cr6+ on most electronics.
All of this is leading to deselection and loss from the market of many of the most widely-used and effective corrosion and wear protective coating chemicals used on military equipment. As a result, the need for alternatives that do not have environmental, safety, or occupational health (ESOH) issues, yet are able to match or exceed the performance of currently used materials, is becoming increasingly acute.
As in our prior workshops, the goal of this workshop was to foster the exchange of information between research organizations, chemical and coating formulators and manufacturers, aerospace/defense repair facilities. The workshop covered all aspects of alternative coatings and surface treatments including:
- Impact of U.S. and European environmental and health regulations on defense acquisition and sustainment
- Cd alternatives for components, fasteners, and connectors
- Cr6+ alternatives for pretreating and sealing, primers, and paint systems
- Light metal protection, Al and Mg anodizing, anodize sealing, and repair
- Hard chrome plating alternatives
- Accelerated test methods and modeling
- Beryllium alternatives
- Coating removal
Archived Meeting Agenda and Read-Ahead Materials:
ASETSDefense 2012: Sustainable Surface Engineering for Aerospace and Defense
San Diego, CA
Afternoon Side Meeting
Cadmium Replacement on Electrical and Optical Connectors | ||
|---|---|---|
Briefing Title | Presenter / Organization | |
1:00 PM | Industrial Options and Chemicals - Zinc-Nickel, Aluminum, EN-PTFE, Black EN Pros and Cons | Mike BarnsteadMacDermid |
1:40 PM | Replacement of Cd on Connectors at Radiall | Gerald TredanRadiall |
2:05 PM | NAVSEA Usage and Testing | Jerilyn Brunson, Erin LaBarreNAVSEA, Johns Hopkins |
2:30 PM | Standardization and Qualification | Lisa HofferDLA |
2:50 PM | Break | |
Issues for Defense Applications: | ||
3:10 PM | NAVAIR Concerns | Amy FowlerNAVAIR |
3:30 PM | OEM Concerns | Joe OsborneBoeing |
3:50 PM | Connector Environmental/Galvanic Testing | Steve BrownNAVAIR |
4:10 PM | Discussion of RDT&E Requirements | |
7:30 AM | Registration & Continental Breakfast | |
Session 1: Drivers: Impact on DoD of Environmental and Health Regulations | ||
|---|---|---|
Briefing Title | Presenter / Organization | |
8:30 AM | Introduction and Welcome | Bruce SartwellSERDP-ESTCP |
8:45 AM | REACH Impacts on Aerospace Materials - U.S. perspective | Scott FetterLockheed-Martin |
9:05 AM | AIA REACH Working Group Update | Scott FetterLockheed-Martin |
9:25 AM | Impact of REACH Regulation on the Global Finishing Market - European perspective | Roger EybelSafran, Canada, France |
9:45 AM | In-service Corrosion Issues in Sustainment of Naval Aircraft | Ricardo MendozaNAS North Island |
10:10 AM | Break | |
Session 2: RDT&E, Service Testing, Authorization, and Implementation | ||
10:30 AM | Naval Aviation Progress in Implementing Non-Hexavalent Chromium Surface Finishes | Craig MatzdorfNAVAIR |
10:55 AM | The Validation and Approval of Chemical Agent Resistant Coatings for DoD Platforms. | John Escarsega, Fred LaffermanARL |
11:20 AM | The Nuts and Bolts of Marine Corps Fasteners | Matt Koch, Andy Sheetz, John Repp USMC, Elzly Technology |
11:45 AM | Overview of United States Air Force Surface Finishing Activities | Elizabeth BermanAFRL |
12:10 PM | Lunch | |
1:25 PM | Erosion-Corrosion Resistant Coating for Gas Turbine Engine Compressor Airfoils | Greg KilchensteinOSD |
Session 3: Reducing Response Time to Regulatory Change | ||
1:50 PM | ONR Structures and Materials Roadmap | Bill NickersonONR |
2:15 PM | Using Corrosion Design Models to Accelerate the Transition of Alternatives | Craig MatzdorfNAVAIR |
2:40 PM | Corrosion Modeling and Testing of Riveted Aluminum Alloy Panels | Lei Chen, Mark JawarowskiUTRC |
3:05 PM | Break | |
3:25 PM | The Role of Computational Methods in Sustainable Knowledge-Based Product Development for Aerospace and Defense | Erik SapperBoeing R&T |
3:50 PM | Implication of Atmospheric Wetness Levels on Corrosion at a Coating Defect During Accelerated Testing | Jim DanteSouthwest Research |
4:15 PM | Technology Transition: The Dynamic Role of the U.S. Army Research Laboratory Coating and Corrosion Offices. | John Escarsega, Fred LaffermanARL |
4:35 PM | Using Surface Treatment Specification Databases to Anticipate and Accelerate Response to Regulatory Changes | Will MartinGranta Design, UK |
5:00 PM | Discussion | |
6:00 PM | Networking Reception | |
7:00 AM | Registration & Continental Breakfast | |
Session 4: Coating Systems | ||
|---|---|---|
8:00 AM | Comprehensive Primer Testing Program | Julia RussellNAVAIR |
8:25 AM | Non-chromate ZVOC Coatings for Steel Substrates on Army and Navy Aircraft and Ground Vehicles | John KelleyARL |
8:45 AM | Implementation of Rare Earth Primers and Pretreatments for Military Applications | Eric MorrisDeft |
9:10 AM | AFRL Update on Status of Cr-Free Coating Systems | Mike SpicerAFRL |
9:35 AM | Commercial Applications of UV Cured Systems | Dave DiehlRadTech |
9:55 AM | Break | |
10:15 AM | Status of the UV Cure Powder Coating Demonstration Project | Chris GeibSAIC |
10:35 AM | Electrocoat Process for Non-Chromate Primers in Department of Defense Manufacturing | Thor LingenfelterPPG |
10:55 AM | Galvanic Corrosion of Aviation Primers | Julia RussellNAVAIR |
Session 5: Corrosion Treatments - Cadmium (Cd) and Hexavalent Chromium (Cr6+) Alternatives | ||
11:15 AM | LHE Zn-Ni Development and Implementation on Landing Gear at Hill AFB | Dave FrederickUSAF |
11:40 AM | Development of Cd Replacement with LHE Zn-Ni on Threaded Fasteners and Components | Jay Randolph, Fred LaguinesES3 |
12:00 PM | Lunch | |
1:15 PM | Environmentally Friendly Zirconium Pretreatment for Department of Defense Applications | Thor LingenfelterPPG |
1:35 PM | NASA TEERM Hexavalent Chrome-free Coatings for Electronics | Matt Rothgeb, Kurt KesselNASA |
1:55 PM | QwikSeal, Pre-Sealed Fastener | Christopher Pavlos, Malcolm ProutySystems Materials Research Corp |
2:15 PM | Break | |
Session 6: Light Metal Protection, Aluminum and Magnesium Anodizing, Anodize Sealing, Repair | ||
2:35 PM | Tagnite PEO Process for Gearbox Overhaul | Bill ElmquistTagnite |
3:00 PM | Nano-Technology Self-Healing Conversion Coating for Magnesium Alloys | Jules SenskeUS Army ARDEC |
3:20 PM | Integrated Computational Materials Engineering Development of Alternative Cu-Be Alloys | Eric FodranNorthrop Grumman |
3:40 PM | Cold Spray for Magnesium Components | Blake Barnett ARL |
4:05 PM | Hexavalent Chromium Free Coatings Projects for Aerospace Applications | Chris GiesekingAMRDEC |
4:30 PM | Conductive Protective Finishes for Magnesium | Debbie MaguireEMI Quality Plating |
4:50 PM | Modified Anodic Aluminum Oxide Finish for Enhanced Chrome-free Paint Adhesion and Polymer Bonding | Jude RungeCompCote Inc |
End of Day | ||
7:00 AM | Registration & Continental Breakfast | |
Session 7: Hard Chrome Plating Alternatives | ||
|---|---|---|
8:00 AM | Electrodeposition of Nanocrystalline Co-P Coatings as a Hard Chrome Alternative | Jack Benfer, Ruben PradoNAVAIR |
8:20 AM | Nickel-Tungsten Alloy Brush Plating Alternative for Hard Chromium | Sid ClouserSIFCO-ASC |
8:40 AM | Progress in HVOF Adoption - Hill Air Force Base | Doug BallUSAF |
9:00 AM | Spallation Resistant HVOF Coatings | Richard Vander StratenES3 |
9:20 AM | Grinding and Superfinishing - Methods and Specifications | Jon DevereauxNASA |
9:40 AM | Chromium Elimination and Cannon Life Extension for Gun Tubes | Frank Campo, Mark MillerBenet Labs |
10:00 AM | Break | |
10:20 AM | Advanced Gun Barrel Coating Program | Brad Buening, Craig Dampier NAVSEA, PEO IWS 3 Consultant |
10:40 AM | Off-Angle Thermal Spray Coating Deposition: Enabling Approach to Coat Small Internal Diameters | Arash GhabchiBoeing R&T |
Session 8: Specifications, Standards, Coating Removal | ||
11:00 AM | Development of Life Prediction Models for High Strength Steel in a Hydrogen Emitting Environment | Ed BabcockBoeing Mesa |
11:25 AM | Atmospheric Plasma Depainting | Peter Yancey Atmospheric Plasma Solution |
11:45 AM | Environmentally Friendly Chemical Coating Removers | Ann LaneBattelle |
12:05 PM | Lunch | |
1:20 PM | Wrap-Up Discussions | |
Adjourn Meeting | ||
