Keith Legg 847-680-9420www.hazmat-alternatives.comhttp://www.asetsdefense.org/Teaming website:www.materialoptions.comKeith LeggRowan Technology GroupLibertyville, IL4/2008 Washington ForumGreening DoD Surface Finishing Operationsklegg@rowantechnology.comAnd, has thou slain the Jabberwock?We still mostly use the oldstandbysVats of Cd andhard chromeOceans ofchromateconversioncoatingsBarrels ofchromatedprimerAlternatives moving toproductionStainless steels,compositesElectroplated Al,ZnNiChrome-freeprimersChromate-freemetallic ceramicsklegg@rowantechnology.comRecent workshopsSurface Finishing and Repair Issues forSustaining New Military Aircraft, Tempe, AZ, Feb2008Chromate Alternatives for Metal Treatment andSealing, Ogden, UT, May 2007Metal Finishing - Addressing EmergingRegulatory Requirements, SERDP/ESTCPPartners in Environmental TechnologySymposium, Washington, November 2006DoD Metal Finishing Workshop, Washington DC,May 2006http://www.materialoptions.comunder Meetingsklegg@rowantechnology.comChromate conversion alternatives – Ogdenchromates workshop, May 2007DoD/industry collaborationMany commercial alternatives available3⁄4Cr3+and non-Cr3⁄4Most Cr3+treatments contain other inhibitors (e.g. V)and nanoparticles3⁄4See Ogden meeting reportSome are equivalent to chromatesAll require much more careful prep and cleaningof surface3⁄4Better training3⁄4Better cleaners?3⁄4Ways of measuring cleanliness?klegg@rowantechnology.comSurface Finishing and Repair WorkshopTemp, AZ, Feb 08PurposeGet answers to question of how to sustainsystems with the various new materials, coatingsand surface treatmentsProvide a forum for engineers to interactFirst of the ASETS Defense follow-on from theHCAT meetings3⁄4Advanced Surface Engineering Technologies for aSustainable Defenseklegg@rowantechnology.comMajor changes and challengesChangesNon Cr primers taking overCd could be mostly replacedtoday with Al and ZnNiHVOF taking over from hard Cr3⁄4For externals3⁄4Electroless Ni for internalsQuick cure (UV cure) topcoats3⁄4Under developmentLow T powder coat primersAlloys to replace CuBeNDI to see everythingChallengesNot comfortable with having noCr6+in the finishNon-chromate finishes requiremuch more careful prepReplace a single technology ormaterial with severalTrainingQual,Qual,Qual !!klegg@rowantechnology.comAlloysAll newactuatorsare highstrength stainless steel or Ti3⁄4No Cd3⁄4Much better corrosion3⁄4Still using Cd for galvaniccompatibility with Al airframesCuBebushings3⁄4F-35 has replaced CuBewith Nitronic 60 throughoutaircraft, except weaponsbay door where >2.5” diabushings are outside sizelimits for Nitronic3⁄4Biodur (CoCrMo) looksbetter than CuBe in practice,even though Fcy is lowerS53 high strength CRESsteel forLanding Gear3⁄4This project clearlydemonstrates the power andspeed of computationalmetallurgyMaterials by Design ratherthan Materials by LuckNew materials in months,not decades3⁄4Designed for landing gear,but may find earlier uses inactuators3⁄4Material cost is an issue forOEMsCost savings accrue tousers, not OEMsklegg@rowantechnology.comCd plate alternativesZnNi electroplateBoeing and Dipsol havedeveloped LHE ZnNi3⁄4Few levelers, brighteners3⁄4Looks good for manyapplicationsAs good as or better than CdCan be put into standardplating lineAlumiPlateOverall best technical CdalternativeBecoming used on F-35, F-22Validation/qual under way forlanding gearNo H embrittlementBest SO2salt fog, SCC, fatigueperformanceRequires enclosed lineSole sourceBoth are drop-insAlumiPlate has best performancebut highest capital costklegg@rowantechnology.comCd Alternative Coating CorrosionPerformance on 4340 Steel*CoatingStressCorrosionCracking(Koscc)SCC RankingAir FatigueRankingCorrosionFatigueRankingAcid SO2 SaltFog, ASTMG85.A4Sputtered AlNot Tested---------≥IVDElectroplatedAl101.0BestBestBestBest (bare)IVD-Al52.7Comparableto CdBestBestLeast among AlcoatingsCd49.5CONTROLCONTROLCONTROLCONTROLLHE Zn-Ni56.2> CdDebitDebit> Cd (bare);Comparable(painted)Zn-6Ni36.8OK (lessdata)DebitDebit---MethodÆRSL MethodASTM E 466;R=0.1; f=10/sASTM E 466;R=0.1; f=10/sASTM G85.A4* Steve Brown, Tempe, 08klegg@rowantechnology.comAlumiPlated connectorsklegg@rowantechnology.comHard chrome plating alternativesHVOF has largely taken over for external areasof aircraft componentsAll new commercial and military landing gearprograms specify HVOF WC-Co or WC-CoCr3⁄4Including F-35, A380, B787Implementation at Hill AFB3⁄4Phase I -Converted 38 components (1-06 to 4-07)3⁄4Phase II-Converting 128 components (1-07 to 6-08)3⁄4Phase III-238 parts identified, work commencingklegg@rowantechnology.comklegg@rowantechnology.comChrome replacement on interiorsCan HVOF coat 1-1.5 diameters deepFor deeper holes, complex shapes increasinguse of electroless Ni-P3⁄4Usually recommend low-P for best hardness withoutheat treat3⁄4Most airframe alloys cannot take 300-400CNanophase Co-P pulse electroplate developedfor internal chrome replacement3⁄4From Integran LLC in Toronto3⁄4In final stages of testing this yearklegg@rowantechnology.comWearin’ o’ the green – F-35 primer chrome-free•Approved Deft44GN098 Cr-freeprimer as F-35Structural Primer•NAVAIR CompletedQualification to MilPRF-85582•Lockheedengineers nowneed specialpermission to usechromated primers•44GN098 used forApache Longbowhelicopterklegg@rowantechnology.comPowder coatingPainting and curing is always slow and limitsturnaround speed in manufacture andmaintenancePowder coating much better performance, buttoo high a cure temperatureNew Low T Cure Powder Coat under transition3⁄4250°F, 30 mins; being reduced to 175°F and movingfrom thermal cure to UV cure3⁄4Inhibitor package, eliminates VOCs and primersNew UV cured topcoats under development byFoster-Miller3⁄4Dry-fly time from days to minutesklegg@rowantechnology.comMg gearboxesAlways a bad corrosionproblemTagnite now being used inplace of Dow Cr6+processes3⁄4Better performance, lesscorrosion, less easilydamagedBeginning to use AlumiPlatedstuds and fittings instead ofCd3⁄4Can re-Tagnite or re-anodizefor better performanceDeveloping cold spray Al forrepair (ARL, DSTO)H-60 Main Transmission Housing showingareas most susceptible to corrosionklegg@rowantechnology.comASETS DefenseHCAT has segued into ASETSDefense(Advanced Surface EngineeringTechnologies for a Sustainable Defense)New name reflects broader mission for allclean surface technologiesNew web site under construction from oldHCAT.org, now calledwww.asetsdefense.orgNew teaming web site for all data andteam interactions still atwww.materialoptions.combut runs on different softwareklegg@rowantechnology.comSurface Engineering DatabaseTo implement clean technologies quickly and efficientlyengineers need ready access toengineering dataonsurface engineering materials and processes adequate formaking engineering decisionsThere are numerous web sites for different agencies, butnone contain real engineering data, production details, etc.aswww.materialoptions.comsite doesNew ASETS Defense passworded website is MS SQLbased and Database will run off it for nowEstablishment of readily available engineering data forsome material will drive release of commercial engineeringdata for others3⁄4If companies want to sell it users need to know all about itklegg@rowantechnology.com•SERDP and ESTCPgenerated data•All other releasable DoDdata we can get our hands on•All commercial datacompanies are willing to giveus•Links to data held by others,e.g. NASF, NMFRC, etc.Surface Engineering DatabaseStart with chromateconversion alternativesklegg@rowantechnology.comSummaryThe main challenges are not lack of alternatives,but getting alternatives qualifiedMany clean technologies often perform betterthan current methods, BUT3⁄4They are lot more sensitive to surface condition andprocess control3⁄4They require more care and trainingClean technologies are moving out into the worldBUT have to move into comfort zone3⁄4Growing experience helps3⁄4Access to good engineering data helpsklegg@rowantechnology.comMore infohttp://www.pfonline.com/articles/030801.htmlChrome-Free Aircraft Finishingby Keith O. LeggMarch 1, 2008http://www.finishingtodaymag.com/CDA/Articles/Cover_Story/