Corrosion Prevention andControl Survey Of

Air Combat Command (ACC)9 Sep – 9 Oct 02

Major Dan BullockChief, AF Corrosion Prevention

and Control Office

DISTRIBUTION A. Approved for public release; distribution unlimited.

2

Overview

• Introduction

• Programmatic findings

• Technical findings

• Recommendations and conclusions

3

Focus

• AUTHORITY

– AFI 21-105, Aerospace Equipment Structural Maintenance

• PURPOSE

– Evaluate ACC’s corrosion program

– Assess condition of aircraft & equipment w/respect to corrosion, and materials & processes

– On-site technical assistance and information exchange

• APPROACH

– Evaluation using AF and command instructions & technical orders (T.O.s)

– Emphasis on survey and not inspection

– Environmental awareness

4

Itinerary

• 33 FW Eglin AFB F-15

• 552 ACW Tinker AFB E-3

• 355 WG Davis-Monthan AFB A-10, C-130

• 27 FW Cannon AFB F-16

• 9 RW Beale AFB U-2

• 2 BW Barksdale AFB B-52

• 347 RQS Moody AFB HH-60, C-130

• Out Briefing HQ ACC/LG

5

Survey Areas

• Aircraft Maintenance

• Environmental Management

• Plans & Scheduling

• Quality Assurance

• Training

6

PROGRAMMATIC FINDINGSPROGRAMMATIC FINDINGS

7

Programmatic Findings

• COMMAND-WIDE PROGRAM

– Overall program good

– Aircraft good

• COMMAND-WIDE AREAS FOR IMPROVEMENT

– Unauthorized spot cleaners

– Loss of large walk-in operational plastic media blast (PMB) booths

• GUIDANCE

– ACC instruction in place – comprehensive

• Recommended formal assignment of Wing Corrosion Manager position – now incorporated

– Good Operating Instructions at bases

8

Programmatic Findings

• QUALITY ASSURANCE

– Good

• Use of Aircraft Structural Maintenance (ASM) personnel for aircraft acceptance inspections

• AIRCRAFT WASH SCHEDULING

– Excellent program

• ACCI 21-105 reporting requirement resulting in good wash scheduling @ most locations

• AEROSPACE GROUND EQUIPMENT (AGE)

– Corrosion programs need improvement

– Exception: Moody AFB – Good program

9

Programmatic Findings

• TRAINING

– ACC Guidance Unclear

• Initial/Recurring Requirements

– Computer-Based Training (Corrosion) not implemented

– Local Programs

• Excellent

– HH-60 Corrosion Training (Moody AFB)

– Wash Video (Tinker AFB)

10

TECHNICAL FINDINGSTECHNICAL FINDINGS

11

Aircraft

• F-15, E-3, A-10, C-130, F-16, U-2, B-52, HH-60

– Good Condition

• U-2s and B-52s in excellent condition

– Leading Edges

• Excellent overall; well maintained, very little damage

12

Structural Maintenance/Corrosion Control

• MATERIALS

– Good use of authorized paints/primers/Alodine

• EQUIPMENT

– PMB cabinets in use; many booths inoperative

– Use of vacuum-assist sanders

• PROCESSES

– Doing touch-ups/repaints for entire unit

• FACILITIES

– Need temperature controlled paint storage

13

Aircraft Wash/Rinse

• WASH

– Facilities: Very good @ most locations

– Scheduling: Good!

– Cleaners/Materials

• Excellent use of proper materials

– New A/C wash pad in use

– Inspections

• Quality Assurance (QA) Involvement

• RINSE

– Eglin AFB is working on getting rinse capability

14

Aircraft Painting

GENERAL CONDITION

• Excellent overall

• Leading edges good overall

• Exception: structural patches

• RECOMMENDATIONS

• Sempens, brush/roller

• Especially for structural repair patches

• AFCPCO working with various vendors for Touchup kits

15

Other Maintenance Activities

• No Significant issues found in:

– Avionics

– Munitions

– Communications/Electronics

– Pneudraulics

16

Aerospace Ground Equipment

• GENERAL CONDITION

– Fair to poor

• TOUCH-UP PROGRAM

– Use of unauthorized materials

• OTHER

– FL-D1 Floodlights - poor prep by manufacturer

– Self-generating Nitrogen Carts

• Moody testing coatings on fiberglass cover

– AGE Contracts

• Need to specify materials IAW T.O. directives

17

Vehicles

• OVERALL PROGRAM

– Varies; T.O.s not specific enough

– AFCPCO and Vehicle Dir. revising T.O.s

• GENERAL CONDITION

– Varies greatly

• PAINT PROGRAM

– Some aggressive in-house programs

• MATERIALS

– Vendor-supplied paint mixing stations

18

Hazardous Materials

• UNAUTHORIZED MATERIALS

– CLEANING COMPOUNDS

• Many unauthorized cleaners in use; authorized alternatives are available, and in use in other shops

– CORROSIVE SEALANTS

– SEALANTS

• Identify by Mil Spec. vs. cure time

• SHELF LIFE

– Must be monitored

19

On-site Technical Assistance

• We provided National Stock Numbers (NSNs) for cleaners, Sempens

• We provided information on solvent cleaning equipment/processes

• We reviewed contracts for painting AGE

20

Summary

• EXCELLENT COMMAND INSTRUCTION

– Command Functional Management Excellent

• AIRCRAFT IN EXCELLENT CONDITION

– However, most AGE needs attention

• WING CORROSION MANAGER

– Recommended adding requirement to command instruction

• T.O. AUTHORIZED MATERIALS

– Understand current T.O. requirements

– T.O.s change rapidly

• FULL FINAL REPORT AVAILABLE AT AFCPCO WEB SITE (https://afcpco.robins.af.mil)