Securing the Availability of Green, Enhanced Coatings for U.S. Army - PowerPoint PPT Presentation

DISTRIBUTION A: APPROVED FOR PUBLIC RELEASE DISTRIBUTION A: APPROVED FOR PUBLIC RELEASE Securing the Availability of Green, Enhanced Coatings for U.S. Army Applications (SAGE-Coat) For ASETSDefense 8 December 2016 Erik Hangeland Program Director, RDECOM Environmental Technology Acquisition Program DISTRIBUTION A: APPROVED FOR PUBLIC RELEASE DISTRIBUTION A: APPROVED FOR PUBLIC RELEASE

DISTRIBUTION A: APPROVED FOR PUBLIC RELEASE What is the problem?  The Army requires:  Capability to perform organic surface coating operations on weapons systems at industrial facilities, motor pools, repair shops and in the field  Continued availability of surface coating products and processes that are ESOH sustainable while also meeting performance requirements  Emerging ESOH challenges include:  Increased scrutiny from regulatory and scientific communities  Previous regrettable substitutions  Uncertainty caused by lack of specification control  Obsolescence with new production runs of legacy systems  Side effects of “smart” coating capabilities  If not addressed:  Continued Soldier/civilian/community exposure to ESOH impacts  Liabilities including lawsuits, NOVs, interruption of operations  Unavailable/unaffordable products due to regulation, PR, market pressure, etc.  Weapon systems not maintained properly may be deemed non-mission capable 2 DISTRIBUTION A: APPROVED FOR PUBLIC RELEASE

DISTRIBUTION A: APPROVED FOR PUBLIC RELEASE Didn’t the Army already solve this?  Sustainable Painting Operations for the Total Army (SPOTA) program was extremely successful  Demonstrated and fielded 30+ new surface coating products  Overhauled the CARC system with higher performing, more sustainable products  Eliminated Army use of TCE and MeCl dip tanks  Paved the way for qualification of sustainable cleaners and thinners  Won SecArmy and SecDef environmental awards, among others  However…  SPOTA focused primarily on eliminating HAPs  SPOTA focused primarily on ground vehicles and support equipment  SPOTA was last funded in 2011 and officially ended in 2013  Many technology gaps remain and continue to emerge 3 DISTRIBUTION A: APPROVED FOR PUBLIC RELEASE

DISTRIBUTION A: APPROVED FOR PUBLIC RELEASE Gaps: Paints & Coatings Challenge Current Products Coming Under Increased ESOH Regulatory and Scientific Scrutiny New Products/Capabilities with ESOH Gaps Area Polyurethane Epoxy Aerospace Zinc-Rich Smart, Multi- All Other CARC CARC Specialty Epoxy Functional Coating Topcoats Primers Coatings Primers Coatings Products Types of Coatings Important Electro- Magnesium Adhesion to the Army Magnetic Stoving Promoters Shielding Enamel Zn Chromate, VOCs, NMP, Targeted VOCs Isocyanates, HAPs, VOCs HAPs, VOCs HAPs, VOCs Numerous Isocyanates Chemicals HAPs, VOCs Distinct Missile Demonstrations Aircraft Numerous Systems Needed Polysiloxanes Reformulate Remove Zn No projects Reformulate Reformulate Reformulate No projects RDECOM Potential to Replace with Exempt Chromate planned with Exempt with Exempt with Exempt planned Adoption of Alternative Isocyanates VOCs VOCs VOCs VOCs DESHE Technologies Process 4 DISTRIBUTION A: APPROVED FOR PUBLIC RELEASE

DISTRIBUTION A: APPROVED FOR PUBLIC RELEASE Gaps: Paint Removers & Cleaners Current Products Coming Under Increased Challenge Current Products Not Controlled by Specifications ESOH Regulatory and Scientific Scrutiny Area Paint Cleaners Removers Types of Coatings Important to the Army Manual Immersion NMP, Methylene HAPs, VOCs, Targeted Methylene Chloride nPB Chemicals Chloride Distinct Hand-Wipe Vapor Parts Demonstrations Cleaners Degreasers Washers Needed Also supportive Benzyl Novel and Benzyl Exempt Novel and Azeotropic COTS of AERTA Alcohol or Emerging Alcohol, VOCs, Cyclo- Emerging Blends, Ionic Aqueous Potential requirement for Hydrogen Alternatives Di-Methyl siloxanes or t- Alternatives Liquids, Solvents Alternative Alternative Peroxide- Esters, Other Butyl Acetate Furans (Standardize) Technologies Products in based Proprietary with Methyl Cleaning and Products Products Amyl Ketone Degreasing Processes 5 DISTRIBUTION A: APPROVED FOR PUBLIC RELEASE

DISTRIBUTION A: APPROVED FOR PUBLIC RELEASE Gaps: Sealants, Adhesives, Ammo Challenge Current Products Not Controlled by Specifications Historic Products Needed for New Production Area Ammunition Sealants Adhesives Coatings Types of Coatings Important Aircraft, Ground Aircraft, Ground Other Ammunition to the Army Missiles and Vehicles and Missiles and Vehicles and Ammunition Sealants Avionics Electronics Avionics Electronics Coatings HAPs, VOCs, Di-Butyl Targeted Chromate HAPs, VOCs HAPs, VOCs HAPs, VOCs Phthalate, Chemicals Compounds HAPs, VOCs Distinct Commercially Small Caliber Small Caliber Small Caliber Small Caliber Experimental Mortar Demonstrations Available Primer Cup Primer Pocket Case Mouth Outer Blank Products Sealant Needed Products Sealant Sealant Sealant Sealant No projects COTS with Reformulate 100% Solids Methacrylate- planned Exempt with Exempt UV-Curable based Potential VOCs or VOCs or Spray Adhesive Alternative Lower Total Lower Total Sealant, Technologies Solvents Solvents Others TBD (Standardize) 6 DISTRIBUTION A: APPROVED FOR PUBLIC RELEASE

DISTRIBUTION A: APPROVED FOR PUBLIC RELEASE What are SAGE-Coat’s objectives?  Develop and demonstrate alternative surface coating products that proactively address known and anticipated ESOH sustainability threats  Preclude product obsolescence, availability and affordability issues stemming from domestic and global regulatory pressures  Avoid $200M in associated compliance and health costs  Reduce 400,000 lbs/yr of VOC emissions from high use primers  Eliminate exposure to isocyanates from 200,000 gals/yr of topcoats  Achieve standardization and quality control of 2,000+ off-the-shelf products  Ensure future leap-ahead technologies are ESOH sustainable  Topcoat Topcoat Transition solutions to 40+ Army and Epoxy Primer Primer USMC installations plus OEMs Pretreatment Pretreatment Substrate Substrate  Enable VOC reductions at facilities 0.8 0.7 0.6 0.5 Green 383 in non-attainment with Ozone NAAQS 0.4 V1 Green Reflectance V2 Green 0.3 0.2 0.1 0.0 0.0 0.5 1.0 1.5 2.0 2.5 3.0 Wavelength (um) 7 DISTRIBUTION A: APPROVED FOR PUBLIC RELEASE

DISTRIBUTION A: APPROVED FOR PUBLIC RELEASE SAGE-Coat Program Plan S&T Dem/Val Key: Tox Eval Spot paint removers Metal-rich primers Partnering W Cleaners CARC primers CARC topcoats A Sealants V Adhesives E 1 FY16 FY17 FY18 FY19 FY20 FY21 FY22 FY23 W Non-Chromated Electromagnetic Shielding Coating HAP-Free, Low VOC Stoving Enamel for Magnesium Substrates A Other Aerospace Specialty Coatings with Reduced HAPs and VOCs Other V Immersion Depainting Alternatives to N-Methyl Pyrrolidone Gaps? E Next Generation Sustainable Cleaning and Depainting Chemistries 2 Non-Phthalate Plasticizers for Small Caliber Ammunition Sealants Sustainable Cement for Production of Mortar Systems 8 DISTRIBUTION A: APPROVED FOR PUBLIC RELEASE

DISTRIBUTION A: APPROVED FOR PUBLIC RELEASE HAP-free, Low VOC Chemical Spot Paint Removers for Army Weapons Systems (SAGE 16-06)  Objective: Eliminate HAPs and reduce VOCs found in CARC spot paint removers  Magnitude of impact:  Eliminate 100% of methylene chloride from Army painting operations  Avoid OSHA requirements for medical surveillance of paint stripping workers  Intended end product: Qualified HAP-free, low VOC products effective at stripping CARC topcoats and primers  Technology:  Primarily benzyl alcohol and hydrogen peroxide-based •Research and gather alternatives commercial alternatives •Finalize test matrix FY16  Some leveraged developmental alternatives (NAVAIR)  Weapon systems impacted: Everything coated with CARC •Evaluate alternatives in laboratory •Demonstrate on boneyard parts  Transition path: FY17 •Provide input for spec revisions  TT-R-2918: Remover, Paint, No HAPs  New specification TBD: Neutral HAP-Free Paint Remover  POC: Jack Kelley, ARL, john.v.kelley8.civ@mail.mil 9 DISTRIBUTION A: APPROVED FOR PUBLIC RELEASE

DISTRIBUTION A: APPROVED FOR PUBLIC RELEASE HAP-Free, Low VOC Zinc Rich Primers (SAGE 16-03)  Objective: Eliminate HAPs and reduce VOCs in newly implemented zinc rich primers  Magnitude of impact:  Projected zinc-rich primer usage up to 100K gals/year  Avoid 50K lbs/year HAP emissions and at least 20K lbs/year VOC emissions based on that usage  Intended end product: Qualified HAP-free, low VOC spray-on zinc rich primers that can be used in depot environments  Technology:  Currently qualified products reformulated to be HAP-free with less than 2.8 lbs/gal VOCs (ideally 2.1 lbs/gal) • Create specification  MIL-PRF-32550 revised to eliminate 3.5 lbs/gal VOC class • Notify vendors of reformulation FY16  Weapon systems impacted: Ground vehicles and ground support equipment • Evaluate alternatives in laboratory and outdoor exposure FY17  Transition path: MIL-PRF-32550: Metal Rich Primer (new specification published 11 Aug 2016) • Complete small-scale demo  POC: Fred Lafferman, ARL, fred.l.lafferman2.civ@mail.mil • Publish revised spec and QPL FY18 10 DISTRIBUTION A: APPROVED FOR PUBLIC RELEASE