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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)