Engineering Test Technology Hexavalent Chromium Alternatives for BDS

Engineering, Test & Technology Hexavalent Chromium Alternatives for BDS AFCPCO Chrome Free Coating System Technical Interchange Meeting Steve Gaydos & Waynie Schuette (Presenter) BR&T- STL | Chemical Technology January 18, 2018 Copyright © 2017 Boeing. All rights reserved. | 1

Organization Name | Hex-Chrome Alternatives BDS (Boeing Defense Systems) Process Specifications: BAC Specifications (Legacy Boeing Aircraft – Seattle, WA) ▪ P 8 A (737) ▪ KC-46 (767) ▪ Chinook H-47 PS Specifications (Legacy Mc. Donnell Aircraft – St. Louis, MO) ▪ F/A-18 ▪ F-15 ▪ Missile and Bomb Programs DPS Specifications (Legacy Douglas Aircraft – Long Beach, CA) ▪ C-17 HP Specifications (Legacy Hughes Aircraft – Mesa, AZ) ▪ Apache AH-64 Copyright © 2016 Boeing. All rights reserved. | 2

Organization Name | Hex-Chrome Alternatives Alkaline Cleaning/Aqueous Degreasing Specification In Approval Process Being Evaluated In Use in Aerospace Title BAC 5763 Emulsion Cleaning and Aqueous Degreasing BAC 5749 Alkaline Cleaning PS 12030 Alkaline Cleaning Key Requirements § § § Ability to clean Water-Break-free surface required (BAC 5749 only) no pitting or IGA State of the technology ▪ All chromated alkaline cleaners have been replaced with non-chromated alkaline cleaners Challenges ▪ Cleaners are not universal, they need to be selected based on the prevalent contaminant Projects in Work Brulin Ultra filtration • remove contaminants • add back surfactants Copyright © 2016 Boeing. All rights reserved. Performance More consistent chemistry and contaminant levels Environment and Safety Chemical reduction Manufacturability Tech Progress Reduce down time Chemical costs | 3

Organization Name | Hex-Chrome Alternatives Etching Cleaning and Etch for Penetrant (Aluminum) Specification In Approval Process Being Evaluated In Use in Aerospace Title BAC 5786 Etch Cleaning of Aluminum Alloys PS 12050. 1 Pickling Aluminum Alloys Key Requirements § § State of the technology Controlled Etch rate Min Surface roughness No End Grain Pitting No Intergranular Attack ▪ All approved solutions are Hexavalent Chrome free Challenges ▪ Some suppliers are not using BAC 5786 solutions and are still use hexavalent-chrome containing acid etch for penetrant ▪ Need a non-chrome etch for copper Projects in Work TEA filtration – solutions are typically dumped due to high smut content interfering with parts or equipment Performance Consistent process conditions Environment and Safety Reduce hazardous waste Reduced chemical handling Manufacturability Tech Progress Reduce down time Are there opportunities with new tanklines to change from acid etching to alkaline etching? Copyright © 2016 Boeing. All rights reserved. | 4

Organization Name | Hex-Chrome Alternatives Anodizing – Approved Alternatives Specification Title Key Requirements BAC 5019 PS Chromic Acid Anodize (CAA) 13201, Type I BAC 5632 Boric Sulfuric Acid Anodize (BSAA) DPS 11. 05 -2 Thin Film Sulfuric Acid Anodize Approved Alternatives BSAA - approved alternative to CAA (drawing and sub-drawing) BSAA and CAA Class 5 – Unsealed Anodize Approved for 100% painted (drawing and sub drawing) Performance Improved process robustness § § Environment and Safety Requires tighter temperature controls and sometimes cooling Requires Dilute Chrome Seal Not approved for other OEM’s Improved robustness Eliminates chrome seal Requires segregation of sealed and unsealed parts Limited to parts that are 100% painted Enables non-chrome deox (if all parts are Class 5) Eliminates salt spray requirement if all parts are Class 5 16 hour time limit between anodize and prime. (BAC 5632, PSD 6 -31) Limited approval for 100% primed thin sheet metal parts No hex chrome Consistent bath chemistry Out of tankline – Spray process No Rinse Cleaning processes still in tankline in most cases Drawing approval for other Bath Life extension BSAA – membrane technology to remove Al and Cu Manufacturability Eliminates hex chrome in anodize bath. Part specific approvals Boegel/BMS 10 -128 (drawing and sub drawing) Salt spray – standalone Salt spray - painted Paint Adhesion No EGP/IGA Reduce hazardous waste Reduce chemical handling Reduce tank down time Electrowinning to remove Cu Copyright © 2016 Boeing. All rights reserved. | 5

Organization Name | Hex-Chrome Alternatives Class 5 Anodizing – Unsealed Time Extension Consideration Facilities Controls § Temporary Protection of Parts § i. e. cover with Kraft paper § Isolated area for Unsealed Anodize Part Storage § Clean (procedure and initialed log book) § Clearly identified (signs, taped off) § For example (taped off floor or contained area) § Dedicated material handling (clean) § Minimize part handling § Minimize part/anodize damage (don’t stack boxes on parts) Administrative Controls § Training § Area cleaning procedures and log (General area and isolated storage area) § Part handling and protection procedures § Discrepancy procedures Need to add unsealed anodize as alternative to MIL-A-8625 for painted parts Copyright © 2016 Boeing. All rights reserved. | 6

Organization Name | Hex-Chrome Alternatives Anodizing – Technology Development In Approval Process Being Evaluated In Use in Aerospace Projects In Work Accelerated Sulfuric Acid Anodize (ASAA) • Unsealed • Sealed Performance Paint adhesion Painted corrosion resistance Environment and Safety Manufacturability Tech Progress Does not contain chromic or boric acid Non-Chrome Seals • Trivalent Chrome (TCP) Eliminates hexavalent chrome seal TCP Seals work at room temperature – significant energy savings Tartaric Sulfuric Acid Anodize TSAA No hex chrome Airbus is expanding usage to replace CAA Fume Suppressant for CAA PFOS Alternative for Fumetrol 140 not available. Scrubber or foam blanket are only options to continue using CAA TBD Failed – no acceptable alternative for Fumetrol 140 Elimination of Fumetrol 140 (PFOS) for CAA has forced switch to BSAA on some BDS parts. Copyright © 2016 Boeing. All rights reserved. | 7

Organization Name | Hex-Chrome Alternatives Chromate Conversion Coating – Approved Alternatives Specification Title BAC 5719 PS 13209 Chemical Conversion Coating for Aluminum and Aluminum Alloys BAC 5663 Sol-gel Conversion Coating for Aluminum Alloys Approved Alternative Boegel/BMS 10 -128 (drawing and sub drawing) Performance Used as adhesion promoter Limited approval for 100% primed thin sheet metal parts Drawing approval for other Does not meet requirements in MIL-DTL-81706 or MILDTL-5541 Copyright © 2016 Boeing. All rights reserved. Environment and Safety No hex chrome Key Requirements § § Salt spray – standalone Salt spray - painted Paint Adhesion EGP/IGA Manufacturability Out of tankline No Rinse Cleaning processes still in tankline in most cases Primarily used as surface prep during final paint on exterior of aircraft. | 8

Organization Name | Hex-Chrome Alternatives Chromate Conversion Coating In Approval Process Being Evaluated In Use in Aerospace Projects In Work Performance Environment Trivalent Chrome • CST-Sur. Tec TCP • Metalast TCP • Luster-On TCP • Socomore TCS/PACS Unreliable corrosion performance on 2000 series Al alloys with TCP (Trivalent Chrome Pretreatment) materials Touch-up • Boegel (No Rinse) • Alodine 871 (No Rinse) • Sur. Tec 650 V (Rinse required) TCP Coating thickness effects primer adhesion and No Hex Chrome corrosion performance Tri Chrome (TCP) Manufacturability No Cr+6 May require specific surface • In process, waste stream, prep processes such as a on part specific deoxidizer* May require secondary processes (seal)* Boegel, sensitive to surface activation procedures (keytones) TCP CC Implemented on Non-Critical Parts per MIL-DTL-5541, Type II *New tanklines should consider extra tank space to accommodate alternative processes Copyright © 2016 Boeing. All rights reserved. | 9

Organization Name | Hex-Chrome Alternatives Titanium Cleaning, Etching, Alpha Case and Penetrant Specification Title BAC 5753 PS 12050. 6 Cleaning, Descaling and Surface Preparation of Titanium and Titanium Alloys BAC 5842 PS 20022. 3 Chemical Milling Titanium and Titanium Alloys In Approval Process Being Evaluated In Use in Aerospace § Key Requirements § § § State of the technology ▪ No HF Free etch cleaners available Hydrogen Pick-up Water-break-free Etch rate Etch uniformity Surface roughness ▪ Membrane technology commercially available to extend bath life (minimize HF usage and handling) ▪ Chrome free alternatives available for most applications and predominantly used Challenges § § Uniform metal removal Hydrogen Pick-up Technologies Bath Life Extension • Diffusion Dialysis Copyright © 2016 Boeing. All rights reserved. Performance Remove dissolved Ti from etch solution for more consistent chemistry and lower contaminant levels Environment and Safety Manufacturability Reduce hazardous waste – minimize tank dumps Reduce down time Chemical costs Additional equipment costs Tech Readiness Progress | 10

Organization Name | Hex-Chrome Alternatives Titanium Conversion Coating Specification Title BAC 5861 Phosphate Fluoride BAC 5665 Sol-gel on Titanium PS 13204 Sol-gel, Alodine 5700 and 5700 Wipes State of the technology ▪ BAC 5665 Sol-gel is approved for most adhesion applications ▪ Base line for painted titanium for 787 ▪ Global Substitution Drawing approved for 747, 767, and 777 for all painted titanium ▪ 737 approved on a case by case basis § Key Requirements § § Adhesion Fatigue ▪ For stainless steel paint preparation, non-Chrome alternatives now allowed per PS 13204 Challenges § Process robustness Projects in Work Performance Environment and Safety Manufacturability Tech Readiness Progress Currently no projects in work Copyright © 2016 Boeing. All rights reserved. | 11

Organization Name | Hex-Chrome Alternatives Stainless Steel Passivation Specification BAC 5625 Title § Key Requirements Citric Acid Passivation § BAC 5753 & 5758 Descale of Ti, Ni, and Co Alloy Parts PS 13001 Citric Acid Passivation § Corrosion Resistance Non-Etching State of the technology ▪ Citric Acid ▪ Alternative for Nitric Acid and Nitric Acid + Dichromate Passivation Solutions – Permitted for most stainless steel alloys ▪ Citric acid solutions used to remove steel shot peen residue from Ti, Ni and Co alloy parts. Challenges § None Projects in Work Performance Environment and Safety Manufacturability Tech Readiness Progress Currently no projects in work Copyright © 2016 Boeing. All rights reserved. | 12

Organization Name | Hex-Chrome Alternatives Chrome Plating Specification BAC 5709 PS 13002 In Approval Process Being Evaluated In Use in Aerospace Title Hard Chrome Plating § Key Requirements § § Challenges § All require drawing approval - changes Alternative Processes Performance HVOF Thermal Spray (BAC 5851) Performs better than chrome plate. Electroless Ni (BAC 5728) Adhesion is not as good as chrome plate. DLC Diamond Like Coating (BAC 5984) Thin coating ( ~5 microns) but very hard (15 to 28 Ga) Tri-Chrome Plating Need to improve microstructure (crack pattern) and adhesion Copyright © 2016 Boeing. All rights reserved. Environment and Safety Manufacturability Wear/lubricity Adhesion Tech Readiness Progress Line of sight process. Cannot do ID surfaces Currently Ni is not regulated Electroless Ni plating solution requires constant maintenance Requires new equipment. Only one supplier approved. No Cr+6 Drop in replacement | 13

Organization Name | Hex-Chrome Alternatives BDS Paint Primers Non-Cr Primers Are Available and are Being Added to BDS Programs on a Case-By-Case Basis ▪ Typically Allowed on Outer Mold Line (OML) ▪ F-15, final paint tie-coat, Deft 44 GN 098 and Deft 02 GN 084 (on hold) ▪ F/A-18, final paint tie-coat, Hentzen 17176 KEP (replaced Koroflex) ▪ Advanced Systems, Deft 65 GN 015 Zero Cr+6/Zero VOC primer (never qualified to MIL-PRF 23377) – Considered for Paint On The Line applications (still a possibility) ▪ Massive Ordnance Penetrator (MOP) – Al parts: MIL-DTL-5541 Type II, MIL-PRF-85528 class N, MIL-PRF-85285 – Steel parts: Sand Blast + MIL-PRF-26915, MIL-PRF-85285 ▪ Joint Direct Attack Munition (JDAM) – Al parts: SA Anodize + HW Seal with MIL-PRF-85582, Type 1, Class N, gray or MIL-P-23377, Type 1, Class N, gray – Steel: Powder Coat ▪ Small Diameter Bomb (SDB) – Al parts: SA Anodize + Ni Acetate Seal – Steel parts: Zn Phosphate – Steel and Al parts: TT-P-2756 A Chromate-free, self-priming, polyurethane coating material (grey), DEFT 03 GY 0369 SELF-PRIMING TOPCOAT, COLOR NO. 36375 Copyright © 2016 Boeing. All rights reserved. | 14

Organization Name | Hex-Chrome Alternatives BDS- STL Paint Primer Non-Cr Primers Are Available and are Being Added to BDS Programs on a Case-By-Case Basis ▪ Typically Allowed on OML ▪ C-17, Deft 97 GY 160 Advanced Multifunctional Coating – Approved for field level touch-up ▪ AH-64 Apache, All surfaces – Deft 44 GN 098, Mil-PRF-85582, Class N ▪ 767 Italian Tanker, OML direct to metal final paint – Deft 02 GN 084, Mil-PRF-23377, Class N ▪ V-22 landing gear bays, Hentzen 17176 KEP ▪ CH-47 Chinook, Final paint tie-coat, Deft 02 GN 084 ▪ KC-46 A Tanker – Under Review Challenges • All Mil Spec non-chrome primers qualified with a chromated surface treatment (chromate conversion coating or chromate sealed anodize) • Will need to requalify all non-chrome primers when non-chrome surface treatments are implemented Copyright © 2016 Boeing. All rights reserved. | 15