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Corrosion Prevention and Control Survey Of Air Combat Command (ACC) 9 Sep – 9 Oct 02

Corrosion Prevention and Control Survey Of Air Combat Command (ACC) 9 Sep – 9 Oct 02. Major Dan Bullock Chief, AF Corrosion Prevention and Control Office. DISTRIBUTION A. Approved for public release; distribution unlimited. Overview. Introduction Programmatic findings Technical findings

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Corrosion Prevention and Control Survey Of Air Combat Command (ACC) 9 Sep – 9 Oct 02

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  1. 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 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 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)

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