Corrosion Prevention and Repair
Corrosion severely impacts system and facility reliability, readiness and safety, and consumes a disproportionate amount of material and labor hours for repair and treatment of corrosion damaged systems and facilities. The cost of corrosion across the DoD has been estimated at over $20B each year. The purpose of this forum is to exchange information on structure and activities of the OSD- and Military Department-level corrosion prevention and control (CPC) programs. Information regarding policy implementation, emerging technologies, and training opportunities will be presented. The process for submitting projects focused on demonstrating and implementing new CPC technologies will be provided. Challenges facing the maintenance community regarding CPC will be discussed.
Call: 888-537-7715 ID: 16161715#
DCO Link: https://connect.dco.dod.mil/jteg-forum/
Agenda
1300-1310: Welcome and JTEG Background – Greg Kilchenstein (OSD-MPP)
1310-1311: Administrative Notes – Debbie Lilu (NCMS)
1311-1325: Effects of Corrosion on DoD Equipment – Rich Hays (OSD-CPO)
1325-1345: OSD Corrosion Policy and Oversight Overview – Rich Hays (OSD-CPO)
1345-1405: Army Corrosion Control and Prevention Executive Overview – Dr. Roger Hamerlinck
1405-1425: Navy Corrosion Control and Prevention Executive Overview – Mr. Matt Koch
1425-1445: Air Force Corrosion Control and Prevention Executive Overview – Dr. David Robertson
1445-1500: Wrap-up and Overview
Each presentation period will be followed by Q&A
Corrosion Prevention and Repair
JTEG Forum Minutes
Event: On 30 March, 2015, the Joint Technology Exchange Group (JTEG), in coordination with the National Center for Manufacturing Sciences (NCMS), hosted a two hour virtual forum on “Corrosion Prevention and Repair”.
Purpose: The purpose of the forum was to exchange information on structure and activities of the OSD and Military Department-level corrosion prevention and control (CPC) programs. Information regarding policy implementation, emerging technologies, and training opportunities were presented, as well as the challenges facing the maintenance community regarding CPC. Additionally, the process for submitting projects focused on demonstrating and implementing new CPC technologies was described.
Welcome: Greg Kilchenstein (OSD(Maintenance), opened the forum with a welcome followed by a brief explanation of the collaborative purpose of the Joint Technology Exchange Group (JTEG) and described the monthly technology forums. Forums are held on the last Tuesday of each month and generally focus on a specific technological capability such as cold spray repair, laser coating removal, and additive manufacturing.
Administrative: The presentations, along with questions and answers, were conducted through Defense Connect Online (DCO) and an audio line. Over 50 participants from across DoD and industry joined in the forum. Questions were sent through DCO and answered by the presenters during the forum. Those presentation slides which are approved for public release, the Q&A, and these meeting minutes will all be available on the JTEG website at https://jteg.ncms.org/ .
Effects of Corrosion on DoD Equipment: Rich Hays (OSD-Corrosion Prevention Office (CPO)) described the impact that corrosion has on DoD equipment. Using figures from a recent study, he explained that corrosion costs the DoD over $23 billion each year. In other words, between 10% and 30% of every maintenance dollar is spent to prevent or correct corrosion problems. Corrosion also has a measurable and significant impact on system availability and directly causes, or is a factor in, many safety mishaps. Rich also explained that CPO-sponsored “Impact of Corrosion” studies can be used as a tool to identify and prioritize areas that need to be addressed
OSD Corrosion Policy and Oversight Overview: Rich Hays provided an executive overview of the OSD Corrosion Organization and what activities they perform. One notable activity is the sponsorship of demonstration/implementation projects throughout the military departments. He also described communication and outreach programs to include the website: www.CorrDefense.org. Lastly, he talked about the investments in the Technical Corrosion Collaboration (TCC) technology investment categories, before leaving us with some final thoughts on corrosion prevention and control.
US Army Corrosion Prevention and Control Program: – Dr. Roger Hamerlinck (OASA(ALT), SAAL-PA) provided an overview which included the organization of the Army Corrosion Board and Army Corrosion Integrated Product Team. He also provided a very informative discussion on the challenges to technology insertion to including environmental dependence, how potential solutions should be authorized/assigned to the end item, funding availability, and whether the technology resolves the root cause of the corrosion.
US Navy Corrosion Prevention and Control Program – Matt Koch (DON,CCPE) described some actions to address corrosion, the role of the Navy Corrosion executive, the corrosion cross-functional team, and corrosion executive focus areas to include communication and collaboration. Matt also briefly described the Navy FY15v Strategic Plan for Corrosion and finished by talking about the Navy’s “Mega Rust 2015” conference to be held in Newport News, VA in June.
US Air Force Corrosion Prevention and Control Overview – Dr. Dave Robertson (USAF, CCPE) talked about the impact of corrosion maintenance costs on the Air Force and the organization of the AF Corrosion Prevention and Control working group. He also described AF CPC enterprise ongoing activities in the areas of: implementation of improved materials and processes, communication and collaboration, information and training, and research. Dave concluded by providing an example of focused technology implementation involving hexavalent chromium replacement.
Observations & Review: – The JTEG Principals provided positive feedback to the presentations emphasizing the importance of sharing these types of technologies across the depots and military services. Rich Hays commented that he appreciated the opportunity to present corrosion control information to audiences outside the corrosion community.
Questions & Answers: Q&A from the teleconference will be posted on the JTEG Website.
Contact Information:
Greg Kilchenstein, gregory.j.kilchenstein.civ@mail.mil
Rich Hays, richard.a.hays18.civ@mail.mil ,
Dr. Roger Hamerlinck, roger.d.hamerlinck.civ@mail.mil
Matt Koch, matthew.e.koch@navy.mil
Dr. Dave Robertson, david.d.robertson10.civ@mail.mil
Next JTEG Meeting: 28 April 2015, 1:00-3:00 pm EST, “Non-Destructive Testing”. This will be a non-public forum and registration will be required to have access.
POC this action is Ray Langlais, rlanglais@lmi.org , (571) 633-8019
OSD Corrosion Prevention and Control
Rich Hays
Answered Questions (7)
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Q1. How much can differences in maintenance capabilities and maintenance echelons impact the aviation mishaps data?
A1. That’s a tough one. I’m not sure we can answer that in that much detail. Safety data is difficult. We need to look at the details of each record.
Q2. Are the dollar figures computed in the same year?
A2. Yes, in baseline years.
Q3. Do we have any data to validate the difference in preventive maintenance compared to corrective maintenance?
A3. We do have that information. I didn’t show it here. We are looking at both preventative and corrective maintenance.
Q4. There are many ways to get to system availability. So, how do we determine the corrosion piece of that? We can have a mountain of parts or a ton of maintenance man-hours to reach a higher level of availability?
A4. We take out a percentage of inspection related solely to corrosion.
Q5. What level of maintenance capability is available on board ship? This is about differences between the services.
A5. Organizational for ships while active and underway. While pier side, it is a mix.
Q6. It was mentioned that if “we could implement what we know today, we could reduce corrosion related maintenance by 30%”. What are those solutions? And, what is preventing implementation?
A6. Budgets drive maintenance reform. Training is another way to improve. There are lots of reasons. The database helps identify areas of concern, but the drawback is that it doesn’t tell us why.
Q7. I don’t understand the Army costs on the H-60 being lower: The army operates about 15 X more H-60s than the Air Force.
A7. The data in the chart is for HH-60 assets only. The USAF has 102 and the Army has approximately150. The bulk of the Army’s H-60 fleet is the UH-60, which is not included in the HH-60 data.
Air Force Corrosion Prevention and Control
Dr. Dave Robertson
Answered Questions (3)
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Q1. How much do the Service CCPEs communicate and coordinate cross-Service to leverage and synergize corrosion prevention and control information and resources?
A1. There are some really good things that the OSD corrosion program does. There are various activities where we share information. For example, the WIPTs meet three times a year now. It is much better than it was 20 years ago.
Q2. For Navy – (Answered by Steve Spadafora on behalf of Matt Koch). – Any thought of an ONR ManTech Center of Excellence for Corrosion Prevention and Control (given the scope of problem and impact)??
A2. Typically, alot of the work is in the ship arena, not so much in aviation and infrastructure. Because of the diverse nature of the problem, there are significant differences in the areas, and subject-matter-experts in each of the different areas. They focus on their specific areas which are often not applicable to other areas.
Q3. What is the best process to get specific projects that address AF wiring corrosion issues into the cue for funding?
A3. There was a “Call for Projects” just sent out. The OSD Corrosion call for projects is conducted annually. There are various requirements which have to be met. The AF POC for the annual OSD Corrosion Project Call is Jeff Nusser. His contact information is below:
Jeff Nusser
SAF/AQR
703-254-2756