1 the painting center of excellence program mark lattner, sea05pf 25 jun 2015 distribution a....

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The Painting Center of Excellence Program

Mark Lattner, SEA05PF

25 Jun 2015

DISTRIBUTION A. Approved for public release: distribution unlimited.

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Painting Center of Excellence

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Corrosion Control

Assistance Teams (CCATs)

PreservationTechnology

Enhancement

A virtual center that develops corrosion solutions for achieving a

reduction in Total Ownership Costs (TOC)

Teams provide tools, training, technical expertise and

technology to Ships’ Force in execution of corrosion control

The Painting Center of Excellence (PCoE) combines a commitment to improved Fleet maintenance through CCATs with products and processes

identified by Preservation Technology Enhancement Projects

Two Parts, One Goal…

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CCAT Capabilities

Tools • Pier-side Preservation Tool Complement & Issue (40’ & 20’ Tool Depots)• Air Compressor Support for Pneumatic Tools• Repair/Maintenance of Ship Surface Preparation Tools

Training• Ship Force Corrosion Control and Tool Use Training – Classroom and OJT

Basic Corrosion Control, Coatings and Tool Training C5I Corrosion Control Training Ship Supervisory (Officer and CPO) Corrosion Control Training Polysiloxane Maintenance and Application

• Train SF on US Navy corrosion control technical requirements per NSTM 631/634 and PMS – Doing the Job Right, the First Time!

Technical Expertise• HM&E & C5I Corrosion Control Experts on the Deck plates providing Technical Guidance

and Oversight for SF work execution.• Support in Planning of Ship Corrosion Control Maintenance

Technology Introduction• Introduce Sailor-Friendly State of the Art Technology

The Four “T’s”

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CCAT Deployment

San Diego – Apr 11

Everett – Apr 11

Norfolk – Mar 10 (CRUDES)

Little Creek – Nov 10(AMPHIB)

Mayport – Feb 11

Yokosuka – Oct 11

Sasebo – Apr 14

Pearl Harbor – Oct 14

Rota – FY17 (proposed)

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CCAT - Making a Difference Projects After 12-24 months

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USS FARRAGUT (DDG 99)

July 2013 July 2013

Feb 2012 Feb 2012

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USS ANZIO (CG 68)

May 2013

May 2013

May 2013

May 2013

June 2014

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USS JOHN S MCCAIN (DDG-56)

January 2013

November 2011

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USS JOHN S MCCAIN (DDG-56)

October 2011

January 2013

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PCoE from Start to Finish

Proposal Request

Project Selection

Technology Developme

nt

Technology Implementatio

n

Proposals, relating to paint and corrosion mitigation, are requested for the following categories:

Design Improvement Logistic Improvement Process Improvement Technology Transition Technology Development

Project Advisory Panel (PAP) is assembled PCoE seeks to gain input from a variety of the communities within the Navy, such as:

- SUBMEPP, SURFMEPP, SEA21, PEO Carriers, Fleet, corrosion Technical Warrant Holders, etc.

PSP ranks proposals via two rounds of voting in preparation for project down-selecting Program Manager (PM) makes final selections based on PAP’s input and ranking

Projects are developed and tested over the proposed funding period PCoE strongly encourages that ship demonstrations be utilized in the testing of the product/technology that is to be delivered

Periodic status updates are provided to the PM

Program delivers Fleet-ready technology to reduce TOC

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1Q 2Q 3Q4Q

1Q 2Q 3Q4Q 1Q…

FY15

38

FY16 FY17

Sprayable Dielectric Shields w/oRemoval of Existing AnodesInstitutionalize the coating process for spraying dielectric shields w/o removing the existing anodes.

474

FYDP ROI

Overboard Discharge Pipe PreservationDetermine and Transition appropriate coating systems for Overboard Discharge Pipes to reduce running rust on freeboard

351.3

FYDP ROI

Marine Sealants MetricsBuild and Quantify the performance requirements for Marine Sealants.

323

FYDP ROI

Wear Resistant AppliquesEvaluate Wear Resistant Appliques for increased service life in high-impact areas aboard U.S. Navy Ships.

465

FYDP ROI

Material and Process Metrics for Abrasive Blast OperationsEvaluate abrasive blasting parameters and develop engineer’s guide to achieve desired surface preparation conditions.

33

31

FYDP ROI

Extending CHT Tank Coating LifeDevelop, test, and evaluate products and methods to extend CHT Tank Coating Life.

481

FYDP ROI

Socialization/Transition of Spray Nonskid TechnologySocialize and transition of spray nonskid technology via Fleet demonstrations.

428

FYDP ROI

47-4939-46

Alternate Thermal Spray WireIdentify and assess existing wire types for Electirc-Arc-Spray (EAS) nonskid to reduce corrosion and installation costs.

364.8

FYDP ROI

Conductive Gaskets for Combat System Corrosion Identify and assess a new gasket materials that provide an electronic group path while excluding the external environment to eliminate operational and maintenance problems associated with corrosion.

45

4.7

FYDP ROI

35-37

Universal LSA Pigment PackageEvaluate and Demonstrate a universal LSA pigment package for MIL-PRF-24635.

436

FYDP ROI

Zinc Rich Primer ImplementationAddress concerns wrt Zinc Rich Primer and implement usage throughout the fleet.

378

FYDP ROI

Decking for Reduced TOCEvaluate, qualify, and implement aesthetically appealing deck coatings to reduce decking TOC.

446

FYDP ROI

Single Component Polysiloxane CoatingsDevelop, test and evaluate single component polysiloxane for qualification to MIL-PRF-24635..

31 12

FYDP ROI

Emergent Coatings Technical InvestigationsEvaluation and analysis of qualified systems and field collected samples to support NAVSEA decision making.

412

FYDP ROI

Forensic Analysis of Coating FailureReview historical coating failures and associated failure analysis procedures, develop sop for field assessment and sample collection and, train field personnel.

402

FYDP ROI

MIL-PRF-23236 Classification for Ship’s Force Friendly PrimersUtilize CCAT experience to identify a Ship’s Force Friendly primer classification.

395

FYDP ROI

Well Deck Corrosion InitiativeInvestigate condition of well decks and identify corrosion and coating issues and associated solutions to reduce TOC.

385

FYDP ROI

Cause & Effect of OsmoticBlistering on Tank & Void CoatingsInvestigate the cause and impact of coating blisters and make revisions to requirements.

304

FYDP ROI

Robotic Equipment for Application of Thermal Spray NonskidProvide operational robotic thermal spray equpiment to support LHD/LHA Integrated Plan for JSF Modernization

342.6

FYDP ROI

Thermal Spray Nonskid SpecificationsImplement specification to govern the materials, applicators, equipment and processes associated with Thermal Spray Nonskid Applications.

493

FYDP ROI

31-3430

Current PCoE Efforts

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Future PCoE Efforts

1Q 2Q 3Q4Q

1Q 2Q 3Q4Q 1Q…

FY16 FY17 FY18

REDI for Coating Application QA/QCFully develop and demonstrate REDI Tools to support tank and void preservation and inspection

1.02Commercial Coating QA Processes

Survey commercial coating applications and other military services QA processes to improve Navy QA processes

9.01

NRL Non-Skid PrimerFormulate primer to reduce cracking and delamination failures during high temperate operational conditions

1.25

Low Temperature Bilge Coatings for Ships Force

4.2

Rapid DFT MeasurementProvide guidance to inspectors on use in the field between the traditional non-scanning method and new scanning method of DFT measurement

0.53

Surface Profile Tool IndustrializationFully industrialize a surface profile tool for the characterization and qualification of deck nonskid coatings to perform QA/QC

1.8

LDSS as a Corrosion Control Upgrade for Topside ApplicationsEvaluate the use of lean duplex stainless steel for topside hull, mechanical and electrical (HM&E) applications as a substitute for stainless steel

0.72

S-CAT Online RecertificationProvide E-Learning for S-CAT Recertification as required by CCAMM in lieu of training at conference events

3.23

Laser Cladding of Triple Offset Torque Butterfly Valve

Evaluate use of laser cladding as an approach to repair the integral seat of nickel-aluminum bronze TOTS butterfly valves per MIL-PRF-32307

0.82

Morphology of Surface Profile Following Water JettingInvestigate the change in morphology of the surface profile of steel that has gone through multiple cycles of only water jetting

4.99

FYDP ROI

Improved Adhesion Testing for MILSPEC Primers and Topcoats

Assess and/or develop alternative test methods for evaluating the adhesion of primers and topcoats

2.0

FYDP ROI

Improved AFFF CoatingsCommercially available coatings with better chemical and impact resistance to MIL-PRF-32171, Type III

22.3Composite Sunshield for Munition Storage Box

Test and implement composite version of sunshield for munition storage box to mitigate corrosion and preservation issues with legacy steel sunshields

1.10

Quantification of Cost Avoidances through ISIS InspectionsQuantify cost avoidances realized through the use of the ISIS inspection system for tank inspections

6.6

FYDP ROI

Empirical Cure Curves for Standard Navy Coatings

Review process for ASTM F-718s and enforcing tighter regulations on cure stages

3.27

COF Procedure DocumentationDocument procedure for use and maintenance of the µ-Deck (round-ball) COF meter

18.4

Wear Resistant Requirement for MIL-PRF-24613

Verify and expand the current wear resistance requirement for MIL-PRF-24613

2.2

LES for Vent LouversUtilize Liquid Electrostatic Spray (LES) coating equipment and high build coatings for topside repair of complex geometry parts

0.48 Aluminum Surface Preparation EvaluationEvaluate coating adhesion and corrosion resistance based on the profile created by different abrasive blast surface prep and media.

5.0

Determine if MIL-PRF-23236, Type VII, Class 17 can be applied below 50ºF

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Osmotic Blistering

Problem

The blistering of tank coating is a coating failure and is added to the corrosion percentage. The size and density of coating blisters that are considered deficient have never been subject to engineering evaluation

Project Status• Research of blister phenomenology complete• Fleet survey of CCIMS data complete• Testing with blistered test coupons complete

• Fresh Water• Alternate Immersion Salt Water• Cathodically polarized to -1VDC

• Ship demonstration planned to evaluate in situ blisters for one year period to validate lab testing

• Change to CCAMM and Sub Maintenance Standard

Objectives and Approach

Conduct a literature study of blister physics and a data survey of all ship tank data to bound the problem. Devise and execute a series of experiments to grow blisters and to evaluate the effects of ship tank lifetime conditions on their growth.

Deliverables White paper report on the formation of blisters Preliminary Test Report Final Report

Benefit to Fleet (Savings) • About 1,000 tanks per year are identified with blisters• 20 percent deferral with better knowledge of blister

failure

PI: William Needham NSWCCD Corrosion and Coatings Engineering Branch

Painting Center of Excellence, PM: Mark Lattner, SEA 05PF, 202-781-1298, [email protected]

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Single-Component Polysiloxane Topside Coating for Touch-Up & Repair

Problem

Silicone alkyds are the only single-component (1K) coating qualified for use by Ship’s Force on Navy surface ships, yet they continue to provide limited long-term exterior durability (i.e., color and gloss retention), chemical resistance, cleanability and adhesion.

Project Status• Tested to MIL-PRF-24635, Type V requirements,

including 2000 hours Xenon-Arc Weatherometer (WOM) testing

• Produced 50+ gallon quantities of the 1K coating using a commercial coating manufacturer

• Performed roll demonstrations on surface ships over prepared silicon alkyd and high solids epoxy primers using Ship’s Force as the applicator

• Performed a spray demonstration on the USS SAN ANTONIO (LDP-17) in Norfolk, VA using a waterfront contractor


NRL has developed a 1K polysiloxane topside coating that outperforms qualified silicone alkyds and 2K polysiloxanes with regard to color stability, provides excellent solvent resistance, and is easily rolled, brushed or sprayed. The goal is to obtain QPD approval and transition to the fleet.

Deliverables Testing to MIL-PRF-24635, Type V, Class 2, Grade B

requirements, including adhesion over high-solids primers

Demonstrations on surface ships using sailors as the applicators

MIL-PRF-24635 approval and transition

Benefit to Fleet (Savings)

Cost savings will be realized by sailors utilizing the 1K polysiloxane topcoat for touch-up and repair instead of silicone alkyds. The 1K’s exterior durability is 5 times greater than silicone alkyds, and thus sailors will paint less frequent.

PI: Erick Iezzi, Ph.D.Naval Research Laboratory

1K Polysiloxane topside coating on the 02 Level bulkhead of the USS CHOSIN (CG-65) after 7 months of service


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PI: Jamaal Delbridge

Problem

Marine sealants are the last line of defense against moisture migration and subsequent corrosion of equipment failures. No comprehensive requirements document exists to capture all these products in a cohesive manner.


Modify an existing climber to carry a variety of preservation tools into bilges, tanks, and other inaccessible areas within Navy ships

Deliverables Generate rough Draft for Marine Sealant PDS Re-structure program to focus on creating new PDS for

corrosion protective sealant applications that do not conform to any military specifications

Revise Marine Sealant PDS to reflect new approach on program objective PDS

Circulate Marine Sealant PDS for Approval

Benefit to the Fleet (Savings)• An appropriate requirements document would establish

technical credibility to procuring and monitoring marine sealants

Project Status• Project initiated beginning of April 2014.• Conducted Teleconference with team members which

resulted in re-structuring program to focus on creating new PDS for corrosion protective sealant applications that do not conform to any Mil specs. New objective is supported by TWH (Mark Ingle).

NSWCCD Corrosion and Coatings Engineering Branch


Marine Sealants Metrics Development

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Materials and Process Metrics for High Performance Abrasive Blasting

ProblemAbrasive blast surface preparation represents the key process to cost and performance control for critical coated areas. Surface cleanliness is primarily visual and surface profile metric (replica tape, etc.) may not sufficiently differentiate performance impacting variables

Objectives & ApproachDevelop data to characterize the impact of variables associated with abrasive blasting materials, profile measurement techniques, and process control parameters on the resultant surface morphology and coating performance

Project Status• Project Kick off in FEB14• Blasting and measurement work (Phase I) completed in

2014• Testing of selected painted panel sets to occur in FY15• Follow-on blasting work executed in April 2015

Controlled blast production rate of larger panels in production facility with blast nozzle mounted to a semi-automated control arm.

Naval Research Laboratory

Deliverables Data report relating blast materials and process

parameters with resultant detailed blast metrics Abrasive blasting guidelines outline

Benefit to Fleet (Savings)• Once implemented, the best practices generated by the

results of this project will result in at least 5% less rework in critical coated areas.

PI: Bob Kogler, Laura Erickson, Colton Spicer


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Robotic Equipment for Application of TSN

Problem

In order to meet the LHD/LHA Integrated Plan for JSF Modernization over the next several years, it is recommended that the US Navy purchase two robotic application systems to be used for thermal spray installation as government furnished equipment (GFE)

Objectives & Approach• Procure two four-head robotic units (Ver. 2.1) used on

USS Wasp DT-II application• Units to be used to coat LHD/LHA decks to prepare for F-

35B and MV-22 operations in landing Spots 2, 4, 5, 6, 7 & 9

• Possibly use for the robotic units on other ship platforms

Deliverables Procurement of two 4-Head gantry robotic systems

Deploy units to support USS AMERICA (LHA 6) application (June-December 2015), as well as additional platforms going forward


• Ensures robot availability for Fleet applications of TSN over the next several years

• Eliminates monthly rental costs

Project Status• Funds applied to contract for procurement• Working with vendor to verify all lessons learned with

the robot are incorporated• Procurement started

Naval Research LaboratoryPI: John Wegand, Ted Lemieux, Jimmy Tagert


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Overboard Discharge Piping

Deliverables Report of Findings – Pipe characterization and potential

solutions End of FY 15 synopsis of project status

Project Status• Shipboard demo on USS GUNSTON HALL (4Q FY 13)

utilizing test commercial coating• Discussions with 3rd party contractor to install NRL

coating to achieve SSPC-SP 10 surface preparation • Investigation into composite piping• Utilization of CCAT to install epoxy coatings onto ship

discharges in Mayport

Benefit to Fleet (Savings)Necessary change in mindset to institutionalize that painting under overboard discharge will not need to be accomplished with every pier stop. Cost savings are from savings in paint and sailors doing their intended job vice being part of paint team. Also there is savings due to weight of paint that is in 80-100 mil range from repeated paint applications to cover up rust stains.

Objectives and Approach• Coating or lining the inner diameter of carbon steel

discharge piping• Short simple geometry piping utilizing T&E coating

system w/applicator designed for coating inside pipe• Long or complex geometry utilizing T&E pipe lining

technology

ProblemOverboard discharges from corroded carbon steel pipes leave long, unsightly rust streaks down the sides of ships with the fleet continuing to spend significant amounts of man-days to paint over problem again and again.

PI: David Meikle



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Alternative Wire Identification for Thermal Spray Nonskid in Support of F-35/MV-22

Problem

Navy-Marine Corps JIPT deemed thermal sprayed nonskid vital to the integration of the JSF F-35B. However, currently one product has been thoroughly evaluated and validated for flight use. Navy reliance on a single product creates availability risks, is cost prohibitive, and limits opportunities to optimize coating performance.


Evaluate/identify new thermal spray wires that increase spray efficiency and decreases application costs. Verify new wire materials for use as high-temperature, extreme-durability nonskid for use on LHD/LHA Class Ships.

Deliverables Validate two alternative wire types for use as flight-deck

nonskid for Amphibious Assault Ships (LHD/LHA Class) to support F-35B and MV-22 operations

Process Instruction documenting the spray parameters and process for each new wire type

Benefit to Fleet (Savings)• Provide product competition and increase availability

• Reduce cost for material and potentially application

Project Status• Completed identification of six candidate materials• Completed first round of testing with commercial product for

optimization of wire • Completed spray-out of test specimens• Received baseline metallurgical and adhesion results on

candidate coatings• Started electro-chemical testing of wire materials• Began coating performance testing (MIL-PRF-24667 and

other)• Plan to demo one candidate wire summer/fall 2015 on USS

AMERICA (LHA-6)


PI: John Wegand, Cameron Miller & Patrick Cassidy Naval Research Laboratory

Atlas Cell Testing

Cross-section of thermal spray

Subscale JSF Burner

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Zinc Rich Primer Fleet Implementation

ProblemPrevious PCoE testing has shown that use of zinc rich primers would be of great benefit to the Navy by reducing material loss and rust runners in hard to coat areas topside. However, concerns must be addressed about application parameters and methods of specification.

Project Status• Completed laboratory test plan.• Completed sprayout of test panels to test zinc primers

over hand tool prepared (repair) areas and polysiloxane/epoxy over aged zinc (extended overcoat). Placed panels in testing.

• Developed demonstration plan for USS SAN ANTONIO (LPD 17) and USS MESA VERDE (LPD 19). Drafted Statement of Work and ordered all coating materials for demos.

Objectives and ApproachDemonstrate previously tested coatings in topside hard to coat areas. Address any application concerns. Conduct laboratory testing to determine maximum overcoat windows. Determine the effectiveness of zinc primers over hand tool prepared surfaces. Determine best method of implementation and specification.

Deliverables Two shipboard demonstrations (one complete blast and

repaint, one repair scenario). Laboratory testing results. Recommendations for specification and implementation.

Benefit to Fleet (Savings)• Reduced costs of topside preservation due to running

rust• Reduced rework (welding and installation) due to

material loss

PI: Jimmy Tagert, Paul Slebodnick and Patrick Cassidy Naval Research LaboratoryZinc Primer Performance Benefits

Epoxy control vs. IOZRunning Rust

Epoxy control vs. IOZMaterial Loss


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MIL-PRF-23236 Classification for Ship's Force Friendly Primer

Deliverables Identify SF friendly coatings through CCAT and

independent research Procure materials (coatings, panels) for testing coatings

identified Generate list of criteria for new classification of primer Perform laboratory testing on 3-4 coatings Develop new requirements for specification based on

CCAT feedback and laboratory data Update and publish specification

Project Status• Identification of SF friendly and not friendly MIL-PRF-

23236 coatings • Procurement of materials• Generate list of criteria for new classification of primer

Benefit to the Fleet (Savings)The updated specification would allow SF to easily identify coatings they can apply. This would prevent SF and CCAT from procuring and applying coatings that are not SF friendly products.

Objectives and ApproachNSWCCD will utilize CCAT knowledge and experience regarding currently qualified MIL-PRF-23236 Type 5 and 15 products in use by SF to identify all coatings for possible use by SF. NSWCCD will create a new SF friendly classification of materials and will update the MIL-PRF-23236 to include this new classification.

Problem With the assistance and training of CCATs, Ship's Force (SF) is beginning to utilize more corrosion resistant and higher solids coatings, specifically MIL-PRF-23236 primers. However, many qualified MIL-PRF-23236 primers are difficult for Ship’s Force to apply due to uneven mixing ratios, short pot lives, high viscosity, and a variety of other factors.

PI: Jennifer Ehrich NSWCCD Corrosion and Coatings Engineering Branch


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Forensic Analysis of Coating Failures in the Fleet

Problem

Coating failures in the fleet impact fleet readiness and requires costly rework. The root cause of the failures must be assessed to prevent future failures.

Project Status• Forensic SOP partially written with more detail and

formatting changes to be added into the current document.

• Forensic analysis testing performed on failed coating samples taken from the field from CVN-68, CVN-73, LCS-6 and CVN-71.


Develop a standard operating procedure (SOP) for coating failure analysis in the fleet detailing sampling techniques in the field and analytical methods/instrumentation to utilize in the laboratory.

The forensic analysis of failed samples from the field to determine the cause of failure.

Deliverables SOP for coating failure analysis Forensic analysis of failed samples from the field


Savings are dependent on the number of failures that occur per year, the success of failure preventions and increased cost due to analytical testing of failed field samples.

PI: Sarah Eppard, James Martin Naval Research Laboratory

Salt contamination identified on a failed sample from LCS-6 by SEM-EDAX (Scanning Electron Microscope-Energy Dispersive X-ray Spectroscopy)


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Transition of Novel and Automated Nonskid Spray Equipment

ProblemSprayed nonskid has shown to provide: 1) faster application times for coating decks and turtlebacks, 2) generation of a more consistent surface appearance with desired slip resistance, and 3) improved corrosion resistance versus rolled, thus providing an improved service-life.

Project Status•USS LABOON DDG-58, Port Side P-way & Boat Deck•USS SAN ANTONIO LPD-17, #5 Fueling Station•USS MAHAN, DDG-72, Forecastle (Sept 2015)•Have briefed SURFLANT N43, RMC, MARMC


Socialization of spray technology via Fleet demonstrations with the overarching objective to further Fleet Transition by working through the Regional Maintenance Centers and Type Commander/Deck representatives to evaluate and validate the benefit

Deliverables Socialization of spray nonskid technology via Fleet

demonstrations to further Fleet Transition, working with RMCs, Type Commander/Deck and IDIQ contracts

Spray demonstration aboard Fleet platform Invite future technology owners, Government, Private

KTRs, Gov & Private Yard QA to demonstrations Installation Report


Cost savings for sprayed nonskid coatings will be realized by providing faster application times and improving corrosion resistance, thus extending the service-life of nonskid coatings.

PI: Paul Slebodnick , John Wegand, James Tagert, Erick Iezzi Naval Research Laboratory


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Detailed MIL-PRF-24635 LSA Pigment Requirement

Problem

Topside polysiloxane coatings contain LSA pigments for reduced thermal loading on ships, however, the types of LSA pigments that are used is not specified. This results in coatings that gradually color shift in different directions (e.g. one manufacturer shifts red, another shifts green), which makes touch-up and repair difficult

Objectives & Approach

Develop a detailed LSA pigmentation requirement to be incorporated in MIL-PRF-24635 for polysiloxane coatings.

Deliverables Modified formulations from commercial coating

manufacturers (qualified to MIL-PRF24635 and others) Identify best performing LSA pigment combination Shipboard/Industrial application of modified

polysiloxanes Pigment requirement for MIL-PRF-24635

Benefit to Fleet (Savings)• Improved exterior durability, all products color fades

similarly• Improve the visual appearance of the ship

Status• Identified 5 pigment combinations for testing• Received modified formulas from 4 commercial coating

manufacturers (testing 2 of the 3 qualified products and two others seeking qualification to MIL-PRF-24635)

• Identified 5 different LSA pigment combinations for testing

• Scaling up pigment formulas at NRL in different resins to test durability

• Testing the modified formulas received to date

PI: James Tagert, Erick Iezzi, Sumi GulatiSolar Reflectance Measurements of Modified Formulas


Naval Research Laboratory

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TOC Reduction of Fleet Decking

Problem

In 2011, NSWCCD and NAVSEA conducted a Deep Dive analysis of deck covering materials to research areas of commonality within decking and develop recommendations to reduce lifecycle costs. The most significant recommendation from this effort was to replace high cost decking systems (like color-flake, vinyl tile, and carpet), where possible, with lower cost high-wear deck paint.

Project Status• Testing material procurement - Complete• Testing kick-off meeting - Complete• Acquire 3rd party testing quotes and sending samples• Laboratory testing


Due to the limited selection of MIL-PRF-32171 high wear deck coatings there has been only limited adoption of this coating system. The project will conduct a Sources Sought Announcement (SAA) for applicable floor coatings which will then be down-selected based on technical data provided by the manufacturers. Depending on the number of selected coatings a number of qualification tests posing the largest hurdles to qualification will be conducted.

Deliverables Test report and data analysis. HHA Request on products meeting test requirements. Qualifying products that meet qualification requirements Acquiring NSNs and updating PMS/SPMIG generation to support

deck coating maintenance. New coatings will be added to list of changes for next NSTM 631

revision.

Benefit to Fleet

By implementing high wear deck coatings, the fleet will save in installation costs, maintenance costs and potential fuel savings due to decreased weight. In addition, these systems can be maintained by ships force in between availabilities.

PI: Allyson Jones NSWCCD Corrosion and Coatings Engineering Branch


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Conductive Gaskets

Problem

Project Status • Laboratory testing showed comparable performance in

corrosion and electrical ground for legacy and new gaskets

• Technical requirements and specifications review completed

• USS IWO JIMA (LHD 7) – 6 gaskets installed May – July 2014

• USS GRAVELY (DDG 107) – 6 gaskets installed July 2014

• USS CARNEY (DDG 64) – 3 gaskets installed August 2014

• Ship demonstration evaluation• Change to gasket Commercial Item Description in

progress


Deliverables Conduct laboratory testing Install gaskets on surface ships Evaluate results at ~ 12 month interval Change requirements documents to allow gasket use

Benefit to Fleet (Savings)• Total applicable topside components 3300

PI: William Needham, Richard Park, Kevin Chasse

• Combat Systems topside components require a ground path for Electromagnetic Interference (EMI) limitation

• A corrosion path is established that is subject to severe degradation in a marine environment

• Demonstrate the corrosion and EMI effectiveness of conductive gaskets in laboratory test and ship trial

• Change the necessary NAVSEA specifications to approve improved corrosion material



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Wear-Resistant Appliqués for High-Impact Shipboard Areas

Problem

Topside high-impact areas of ships are repeatedly subject to constant impact and abrasion due to equipment operations with ropes and chains. Coating systems installed over these high-impact areas fail immediately after abrasive equipment is re-installed.


The USMC has recently completed a study looking into the use of wear-resistant appliques over high-impact areas. This current project aims to leverage the USMC work and test top performing products identified during the study with topside coating systems.

Deliverables Perform laboratory testing Perform ship trial with best performing applique(s) Provide final report


Cost savings will be realized through lowering the number of repairs needed in high-impact areas and making needed repairs faster and more cost efficient.

Project Status• KTR completed laboratory testing• KTR drafted laboratory test report• Ship trial aboard USS MASON (DDG-87) began 22

May• Ship trial aboard USS BARRY (DDG-52) began 08

June

PI: Ben Bouffard NSWCCD Corrosion and Coatings Engineering Branch


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Monitoring of Sprayable Dielectric ShieldsWithout Removal of Existing Anodes

Problem

The use of spray applied dielectric shields without removal of existing anodes requires leaving Capastic around the anode. The approved MIL-PRF-23236 sprayable system has not been used in conjunction with prior in-service Capastic and its performance under long-term ICCP exposure is unknown.

Project Status• Provided instruction for documentation of all dielectric

shields on USS JOHN C. STENNIS (CVN-74)o Diver inspection completed on 18 FEB 15 and all

pictures obtained• Gathered diver report data on all ships with sprayable

dielectric shields installedo Created spreadsheet to track and evaluate

performance (11 ships total)• Initiated request for dielectric shield application on

candidate surface combatant


Collect data and monitor performance of all ships with sprayable dielectric shields and complete additional field demonstration in support of potential validation for the procedure of applying a sprayable dielectric shield without removal of installed ICCP anodes

.Deliverables Trip report detailing ship check onboard USS JOHN C.

STENNIS (CVN-74) Collection and analysis of sprayable dielectric shields on

applicable ships Coating application on candidate surface combatant


Expanded use of sprayable dielectric material will provide ease of application in addition to improved coating uniformity, fewer film defects, and prolonged service life. This faster application method will give maintenance planners more time flexibility in scheduling repairs as well as faster turnover of these areas to other trade work.

PI: Carly Snyder, David Fayocavitz NSWCCD Corrosion and Coatings Engineering Branch

In-service sprayable shield on CVN-74 (11 months after install)


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CHT Coating Qualification/Examination

Problem

Chemical Holding & Transfer (CHT) tanks coating systems fail prior to scheduled refurbishment which results in costly repairs to corroded steel to maintain integrity. Aboard ship, CHT tanks hold various chemicals and reactant solutions which often rapidly degrade the coating system.

Project Status• FY15 First Demonstration coating identified and

demonstration being scheduled.• Application of additional systems beyond original three

systems underway.• Testing will commence once application & cure is

complete.• Examination of ASTM G 210, “Standard Practice for

Operating the Severe Wastewater Analysis Testing (SWAT) Apparatus” as a potential performance test for MILSPEC.


Test eight high performance coating systems for CHT use via qualification testing, down select and demonstration best three. Examine qualification testing criteria and develop better performance tests for MILSPEC update.

Deliverables Short Term Status Report (90 days after start of

testing) Demonstration Installation Report One-year in service Demonstration Report Final Report for each Coating SystemBenefit to Fleet (Savings)

CHT tanks are required by US Federal Law. By using better coating systems the Fleet can generate a cost avoidance by extending the period between refurbishments for CHT tanks. Additionally better coating systems translate into less risk of leaks, hazards to personnel, and chance of pollution in the environment.

PI: Ivan Stanke Naval Research Laboratory


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Thermal Spray Nonskid Specifications

Problem

With the proposed implementation of thermal spray nonskid in the fleet, specifications are needed to govern the materials, system qualification process, applicators, application equipment and process.

Project Status• Completed meetings with NAVSEA TWH for welding and

coatings to review process map.• Initiated review of MIL-STD-1687A and MIL-PRF-24667

in addition to other commercial specs and canceled mil standards.

• Completed outline of Standard Item, started first draft.• Completed outline and first draft of MIL-PRF. Started

second draft.• Started draft of addendum to process standard.


Develop a Standard Item to oversee the entire thermal spray nonskid process. Draft proposed changes to manufacturing process specification MIL-STD-1687A for field application processes and applicator qualification. Develop a military performance spec (MIL-PRF) to govern qualification of thermal spray systems and materials.

Deliverables Draft Standard Item Draft MIL-PRF Draft changes/addendum to MIL-STD-1687A


Provide process control for the entire thermal spray nonskid program, reducing risk of failure/rework.

PI: John Wegand, Jimmy Tagert and Patrick Cassidy Naval Research Laboratory

Thermion RDM-4 Robot


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Naval Surface Treatment Center

Problem

There is need for an on-line source of preservation-related information for use by naval shipyards, Supervisors of Shipbuilding, Regional Maintenance Centers, other maintenance activities, product manufacturers, and contractors performing preservation work aboard U.S. Navy ships and submarines.

Project Status• Backend redesign for NSWCPL updating – Completed.• Analysis of website survey data – Completed.• Content updates, informed by survey data • Low bandwidth website for underway access • Mobile website

Objectives and ApproachDevelopment, operation, and maintenance of the Naval Surface Treatment (NST) Center website, www.nstcenter.biz. This is an unclassified website that is open to the public. It is sponsored by NAVSEA 05PF.

Deliverables Upload of backend redesign Analysis of website survey data Content updates Document updates (ASTM F718s)

Benefit to Fleet (Savings) Updates to documents will be necessary throughout the lifetime of this website. Impact of not updating documents and content housed on the website would result in increased potential for catastrophic or premature coating failures.

PI: Allyson Jones NSWCCD Corrosion and Coatings Engineering Branch


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Questions or Comments?Mark Lattner, SEA05PF

[email protected]

(202) 781-1298

Graig Jolley, NSWCCD

[email protected]

(215) 897-1786

mailto:[email protected]

mailto:[email protected]

1 the painting center of excellence program mark lattner, sea05pf 25 jun 2015 distribution a....

Documents

execution of corrosion

corrosion solutions

corrosion mitigation

toc slide

goal slide

ts slide

ojt basic corrosion

art technology