NAVAL SEA SYSTEMS COMMAND Whats New in Coatings NSRP SPC Panel - - PowerPoint PPT Presentation

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NAVAL SEA SYSTEMS COMMAND What’s New in Coatings

NSRP SPC Panel Meeting Charleston, SC March 2016

• Mr. Mark Ingle, P.E.

SEA 05P2 (202) 781-3665 mark.w.ingle@navy.mil

Distribution A: Approved for Public Release

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OBJECTIVES

• Summarize evolving Naval Sea Systems Command (NAVSEA) organization

and coating requirements:

• • Headquarters NAVSEA organization & objectives.
• Summarize what’s new in NAVSEA coatings and life-cycle cost reduction

strategies:

• • FY-17, Change 1, Standard Item 009-32 to be published to address

high-priority issues.

• • Nonskid requirements evolution and ongoing lessons learned.
• • New Thermal Spray Nonskid (TSN) materials to reduce total life

cycle costs.

• Discuss opportunities for NSRP to support new ideas and new TSN requirements.

Distribution A: Approved for Public Release

Naval Systems Engineering Directorate (SEA 05)

Technical Domain Manager (TDM) Chief Systems Engineer (CSE) Office of the CHENG

SEA 05B Deputy / COS (SEA 05B1) Aircraft Carrier Design & Systems Engineering (SEA 05V) Chief Finance Office (SEA 05B3) Surface Ship Design & Systems Engineering (SEA 05D)

Integrated Warfare Systems Engineering (SEA 05H)

Cost Engineering & Industrial Analysis (SEA 05C) Ship Integrity & Performance Engineering (SEA 05P) Chief Workforce Office (SEA 05B2) Special Projects (SEA 00U/05X) Executive Director / CHENG Deputy / Chief Technology Officer (SEA 05B) Littoral and Mine Warfare Design & Systems Engineering (SEA 05L) Technology Office (SEA 05T) Submarine/Submersible Design & Systems Engineering (SEA 05U) Technical Policy & Standards (SEA 05S) Undersea Warfare Systems Engineering (SEA 05N) (NUWCNPT TD) Surface Warfare Systems Engineering (SEA 05W) (NSWCDD TD) Marine Engineering (SEA 05Z) L&MW Warfare Systems Engineering (SEA 05M) (NSWCPC TD) Explosive Ordnance Engineering (SEA 05E) (NSWC IH TD) T&E Technical Advisor

Deputy Commander / CHENG

(SEA 05) Chief HR & Admin Office (SEA 05B6)

Draft: As of 8/28/15 3

Distribution A: Approved for Public Release

Code Product Related Specs

All All Technical Products, Managerial All AF Antifouling Coating Systems MIL-PRF-24647 TNK Tank Coatings, Epoxy Primers MIL-PRF-23236 MIL-DTL-24441 PRM Primers, Single Component TT-P-645 TOP Topside, Alkyds & Polysiloxanes MIL-PRF-24635 INT Interior Coatings (SEA 08) MIL-DTL-24607 MIL-PRF-24596 MIL-DTL-15090 MIL-DTL-1115 HT High Temp Coatings, Metallic TT-P-28 PWD Powder, Interior, Cosmetic MIL-PRF-24712 NSK Nonskid MIL-PRF-24667 DCK Deck Coverings MIL-D-3134 MIL-PRF-3135 MIL-PRF-24613 MIL-PRF-32171 SUR Abrasive blasting, surface prep MIL-A-22262 SEL Sealants & Preservatives MIL-PRF-16173 NAVSEAINST 9630.1 DOC Policy Documents NSTM 631, NSTM 634 S636-MAN, CCAMM Standard Item 009-32 Standard Item 009-26 COR Corrosion/PCOE Policy/Design DODI 5000.67 RSH Research & Development To be determined UNDS Regulations, Underwater hull TBD NAVAIR Aircraft Engines TWH: Habitability SEA 08R

TWH: Underwater Hull Husbandry SDMs: Surface, Submarine, Carrier

Technical Authority Pyramid - Coatings & Corrosion Control

Draft: Feb 2016

Navy Employee Navy Developmental Employee Contractor Ingle all

Castle (EM) All, COR Lemieux (EA) All, RSH Vacant (EM) NSK, All Wegand (EM) RSH, NSK Lattner (EM) COR Haslbeck (EM) All, AF

• J. Martin

(EM) TOP, TNK Melhuish (EM) All, NSK Brinckerhoff (EM) All Tagert (EM) TNK, NSK Kenney (EM) VA-Class Jones (EM) NSK, DCK Iezzi (EM) RSH TOP Smith (EM) UNDS Wigle (EM) CCAT Slebodnick (EM) RSH,TNK, NSK Merlino (LE) DOCs Chasse (LE) COR Thomas (LE) COR Clayton (LE) DOCs Lawrence (LE) AF Langaster TNK Holm AF Adams (LE) NSK, RSH Bouffard COR Zuwiala COR Ciscon All Park DOCs Foster All Stanke RSH, All

• F. Martin

HT Eppard TNK, NSK Needham (LE) COR, All Webb RSH Intern All Ellor COR Ault TNK, RSH Steinberg (LE) AF Ranero (EM) All, NSK

EAs EMs LEs

Kogler SUR

TWH

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Delegated signature authority

Ong (EA) All McKelvey (EM) COR, DOC Duckworth (EA) All Distribution A: Approved for Public Release

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Standard Item 009-32 Update and Status

• Completed SSRAC meeting in July 2015 to prepare FY-17 Standard Item 009-32.

Concurrence 85% complete – leadership intends to limit use of haze gray silicone alkyd. “Top Ten” Items:

1. RETAINED plan to update potable-water tank rinse requirement language to allow cleaning with white rags and potable water instead of two fill-&-rinse cycles. 2. PROHIBITED use of steel shot on LHA, LHD, LPD, and LSD (expanding on the current prohibition for nonskid work) to mitigate the risk of waterfront misinterpretation of requirements. MORE TO FOLLOW 3. RETAINED approval of rapid-cure, single-coat, potable-water tanks (with qualified MIL-PRF-23236, Type VII, Class 9/18 in white or off-white), submarine sanitary tanks, carrier tanks, and surface ship tanks. 4. APPROVED the use of low-temperature primer under Peel & Stick nonskid (for primer only, not for application of the peel & stick nonskid). 5. RETAINED Appendix C to allow option for NSRP project, final product of “spot and sweep” surface preparation on the underwater hull and freeboard if approved by the SUPERVISOR.

Distribution A: Approved for Public Release

Update Items:

6. DEFINED “DDG-51 Class top of stacks (i.e., 05 level weather decks and bulwarks)” and “Valve Regulated Lead Acid (VRLA) battery compartment at conversion” as critical coated areas.

Deck around BLISS Caps corroding with premature coating failure.

Validated with TYCOMs that cost increase justified to reduce corrosion risks. 7. RETAINED requirement to delete stripe coat and use edge-thickness measurements (stripe coating still allowed, but checkpoint eliminated by additional edge thickness data) for MIL-PRF-23236, Type VII coatings. 8. APPROVED revision to Figure 2 requirement for 2-3/8-inch square masking around bolt hole during RAST track nonskid install, to allows either greater masking overlap or to allow circular masking. 6

Standard Item 009-32 Update and Status

Distribution A: Approved for Public Release

Standard Item 009-32 Change to Allow Round Masking on RAST Track Nonskid

• FY-16, Change 1, Standard Item 009-32 published on 10 JUL 2015

cites Figure 2 that required square masking:

• Approved change allows a round mask as already

installed on some DDGs and approved by NAVAIR: 7

Update to Standard Item 009-32

Current square masking Old Figure 2 from FY-16 New Figure 2 from FY-17

Round Mask on DDG 109

Distribution A: Approved for Public Release

8 Updated Items:

• 9. RETAINED “or NAVSEA-approved equivalent” to allow use of other paperless QA programs.
• 10. RETAINED/UPDATED required coating thickness ranges so that only integers are used

(no decimals).

• 11. RETAINED requirement that 50% relative humidity is applicable only until cure to recoat of final
• touchup. Full creditable cure time may be achieved at 85% relative humidity through cure

to service.

• 12. In addition, have multiple EDITORIAL updates and clarifications to:
• Definitions of terms.
• Capastic Shields.
• Arresting Gear Sheave Foundations.
• Bilge coating requirements to allow SP-3 & SP-11.

SEA 05P2 Comments from all SEA 04 & SEA 05 activities completed and incorporated.

Standard Item 009-32 Update and Status

Distribution A: Approved for Public Release

Summary: Use process & equipment demonstrated on USS WASP (LHD 1) since April 2011 and on USS BATAAN (LHD 5) to apply TSN. Application Plan: Apply TSN to Landing Spots 7 & 9 (as on LHD 1). Apply TSN to areas that will be under V-22 engine nacelle impingement zones at Landing Spots 2, 4, 5, & 6. Status: Thermal spray application complete. Final color top and markings to be applied to the Spots 7 & 9 in March 2016 Risk assessment of baseline TSN material & processes signed out on 5 Jan 2015 with defined MEDIUM level of risk. Updated risk assessment signed on 22 June 2015 to use Arctec 28E TSN. Updated patch design signed on 19 Feb 2016.

Flight Deck Nonskid on USS AMERICA (LHA 6) NEW Thermal Spray Nonskid (TSN) To Improve Flight Deck Performance

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Distribution A: Approved for Public Release

Flight Deck Nonskid on USS AMERICA (LHA 6) Why Use TSN To Improve Flight Deck Performance?

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TSN is only material that can withstand direct F-35 exhaust gas impingement. TSN has low macro- profile and smaller “chips” that can break off lowering risk of aircraft engine FOD. TSN is aluminum and small (e.g., 400 grit or smaller) Al2O3 aggregate as compared with 24-30 grit Al2O3 in conventional epoxy nonskid.

Conventional Nonskid Chips TSN, wear particles , 400 grit aggregate

TSN can resist V-22 exhaust gas heat. NRL validating that V-22 exhaust gas impingement can crack conventional nonskid.

Distribution A: Approved for Public Release

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TSN Technical Requirements Being Developed

NAVSEA GOAL: leverage technical community expertise to develop new requirements.

TSN Fielding Vital to Amphibious Ships & Fleet Operations FY-18 New NAVSEA Standard Item New military specification for thermal spray nonskid materials. Update Naval Ships Technical Manual Chapter 634

Material Installation Process / Qualifications In-service

2016 SSRAC Meeting VASIC Under review by NAVSEA To be developed based on LHA/LHD lessons learned Update Military Standard 1687A NAVSEA working to publish

Distribution A: Approved for Public Release

Background: Develop MIL-PRF-XXXXX to define the wire material used with twin-wire arc spray process & equipment demonstrated on USS WASP (LHD 1), USS BATAAN (LHD 5), and ongoing demonstration on USS AMERICA (LHA 6). Key Specification Provisions: Coating to be formed over SSPC-SP 5 white metal level of cleanliness by automated twin-wire arc system. Multiple coats of TSN acceptable to build coating. Wire material Type/Class to account for chromium levels. Wire material Type/Class to account for hazardous heavy metals. Wire material Type/Class to define whether wire is solid or cored. Qualification Tests: Conformance tests (e.g., metals levels, lubricants, packaging) to be conducted on wire feed stock. Coating conformance tests for silicate color topping. Qualification testing on coating with application parameters demonstrated on LHD 1, LHD 5, and ongoing on LHA 6. Status: NRL draft specification complete. SEA 05P2 preliminary review complete with reading session planned for March 2016. Military specification is to have qualified products list for wire feed materials that can form TSN coatings.

Material Improvements in Nonskid New Thermal Spray Nonskid (TSN) NEW Material Specification

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Distribution A: Approved for Public Release

Military Specification to Define TSN Wire Types/Class Solid Wire and Cored Wire

• LHA 6 TSN being installed using solid wire that is 97% Al / 3% Ti.
• LHD 1 and LHD 5 coated with TSN using cored wire that is 5054 Al jacket / aluminum oxide (400 grit) core.

Cross Section: solid core aluminum wire with elemental Ti. Cross Section: hollow core aluminum alloy wire with aluminum oxide particles. Transfer Efficiency: 68% Transfer Efficiency: 57% Application Rate: 84 - 112 ft2/hour Application Rate: 84 - 112 ft2/hour No reportable chromium on MSDS. Chromium reported as 0.15 – 0.35% Military specification to address Types or Class for both solid and cored TSN wire.

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Distribution A: Approved for Public Release

Re-establishing Profile Using Aluminum-oxide Abrasive Blasting

As-exposed condition after UHPWJ cleaning, extensive corrosion undercutting, atypical for 2-year old nonskid. SSPC-SP5 white metal level of cleanliness with surface profile of 4.5- to 5.0-mils.

• Nonskid installed over steel shot SSPC-SP 10 with OQE indicating profile satisfied requirements.

MIL-PRF-24647D, Type I nonskid (notional 1-year service life) installed on flight deck. TSN application processes demonstrating effective production of SSPC-SP 5 using aluminum-oxide media.

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Distribution A: Approved for Public Release

Background: Develop NEW Standard Item 009-XX to define the twin-wire arc spray process & equipment as demonstrated on USS WASP (LHD 1), USS BATAAN (LHD 5), and ongoing demonstration on USS AMERICA (LHA 6). Status: NRL draft specification complete. SEA 05P2 preliminary review complete with reading session planned for March 2016. Standard Item 009-XX will define detailed process, with G-points, to ensure successful application of TSN nonskid coatings.

New Thermal Spray Nonskid Standard Item Process Summary

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Distribution A: Approved for Public Release

Background: Develop Standard Item 009-XX to define the twin-wire arc spray process & equipment as demonstrated on USS WASP (LHD 1), USS BATAAN (LHD 5), and ongoing demonstration on USS AMERICA (LHA 6). Status: NRL draft specification complete. SEA 05P2 preliminary review complete with reading session planned for March 2016. Standard Item 009-XX will define detailed process, with G-points, to ensure successful application of TSN nonskid coatings.

New Thermal Spray Nonskid Standard Item Define Coats

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Distribution A: Approved for Public Release

Background: Develop Standard Item 009-XX to include citations of provisions for HEPA filters and emission controls to satisfy San Diego, CA Air Quality Management District requirements. Status: NRL draft specification complete. SEA 05P2 preliminary review complete with reading session planned for March 2016. Standard Item 009-XX will define detailed process to ensure environmentally compliant application of TSN nonskid coatings.

New Thermal Spray Nonskid Standard Item Address Regulatory Compliance Issues

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Distribution A: Approved for Public Release

Background: Develop Standard Item 009-XX to include unique QA/QC provisions for validating adhesion of TSN to deck. Status: NRL draft complete. SEA 05P2 preliminary review complete with reading session planned for March 2016. Standard Item 009-XX will define new in-process OQE techniques to ensure TSN is adherent to the deck.

New Thermal Spray Nonskid Standard Item Unique QA/QC Provisions

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Distribution A: Approved for Public Release

Background: Update MIL-STD-1687A requirements for training and qualification of personnel and processes used to apply wire material with the twin-wire arc spray process & equipment demonstrated on USS WASP (LHD 1), USS BATAAN (LHD 5), and ongoing demonstration on USS AMERICA (LHA 6). Key Update Provisions: Defines required applicator training. Outlines safety requirements. Defines applicator qualification process and audit For Quality Assurance/ Guides the applicator through the entire process including containment, legacy nonskid removal, surface preparation, TSNS application, color topping, legacy nonskid tie-in and repair/maintenance procedures. May reference a CID to define the kind of robots used in the process. Status: NRL draft specification complete. SEA 05P2 preliminary review complete with comments. NRL/NSWC moving forward with final update. Update to military standard update will leverage existing thermal spray training and certification requirements for TSN.

New Thermal Spray Nonskid Update to MIL-STD 1687A Qualifications

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Distribution A: Approved for Public Release

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Conclusions

• NAVSEA goal is to improve nonskid system performance while

reducing the risk of aircraft engine FOD.

• NAVSEA publishing FY-17, Change 1, Standard Item 009-32 in March 2016:
• • Steel shot prohibition on LHA, LHD, LPD, LSD.
• • Updated critical coated area requirements.
• • Updated profile measurement requirements.
• NAVSEA working with NSRP, NRL, NSWC and waterfront maintenance

managers to develop new TSN processes.

• NAVSEA to continue efforts to support NSRP initiatives.

Distribution A: Approved for Public Release