2017 AIR FORCE CORROSION CONFERENCE Corrosion Policy, Oversight, & Processes

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1 2017 AIR FORCE CORROSION CONFERENCE Corrosion Policy, Oversight, & Processes Rich Hays Photo Credit USAFA CAStLE Deputy Director, Corrosion Policy and Oversight Office OUSD(Acquisition, Technology and Logistics)

2 Degradation of materials negatively impacts: Cost Availability Safety It s Just Rust Right? Annual cost of corrosion ($B) Corrosion as a percentage of maintenance Annual non-available time attributable to corrosion Average non-availability per end item attributable to corrosion Army Ground Vehicles $ % 662,649 days 1.7 days Marine Corps Ground Vehicles $ % 209,115 days 3.3 days Navy Ships $ % n/a n/a Army Aviation and Missiles $ % 1,717,898 hours 17.4 days Navy and Marine Corps Aviation $ % 95,237 days 26.5 days Air Force Aviation and Missiles $ % 2,102,476 hours 15.9 days DoD Facilities and Infrastructure $ % n/a n/a All other DoD $ % n/a n/a

3 Corrosion Performance is Additive The corrosion performance of aviation systems is a result of activities that occur throughout a system s life cycle. Policies related to the management and mitigation of corrosion drive decision making across a system s life cycle. New technologies and materials developed as part of S&T programs can improve performance of future systems. Design trade decisions made during acquisition often result in reduced corrosion performance in order to meet other performance requirements. The maintenance and sustainment community faces numerous corrosion control challenges including high operational tempo, increasing environmental regulation, and aging fleets.

4 How Many Laws Govern Corrosion? 2 nd Law of Thermodynamics Every process occurring in nature proceeds in the sense in which the sum of the entropies of all bodies taking part in the process is increased. In the limit, i.e. for reversible processes, the sum of the entropies remains unchanged. (Planck) 10 U.S.C the deterioration of a material or its properties due to a reaction of that material with its chemical environment.

5 Corrosion Examples General and Crevice Corrosion of Steel Degradation of fabrics in tropical environment Alkali-Silica Reaction in Concrete Environmentally Influenced Cracking uv Degradation of Organic Coating System 5

6 Title 10 U.S.C Directs CPO Efforts Coordinate efforts throughout DoD to prevent and mitigate corrosion of the military equipment and infrastructure Duties include: review the programs and funding levels proposed by each military department for the prevention and mitigation of corrosion provide oversight and coordination of the efforts to prevent or mitigate corrosion during the design, acquisition/construction, and maintenance of military equipment and infrastructure. monitor acquisition practices to ensure use of corrosion prevention technologies and treatments are fully considered during R&D in the acquisition process and incorporated into that program, particularly during the engineering and design phases. Additionally authorized to: develop corrosion training, relevant directives and instructions, interact directly with the corrosion prevention industry, trade associations, other government corrosion prevention agencies, academic research and educational institutions, and scientific organizations engaged in corrosion prevention Through a long-term strategy to: collect, review, validate, and distribute information on proven methods and products relevant to the prevention of corrosion of military equipment and infrastructure coordinate a research and development program for the prevention and mitigation of corrosion for new and existing military equipment and infrastructure transition new corrosion prevention technologies into operational systems through memoranda of agreement, joint funding agreements, public-private partnerships, university research and education centers, and other cooperative research agreements. Activities Research Opportunities Demonstration- Implementation Projects 6

7 DoD Corrosion Organization Under Secretary of Defense Acquisition, Technology, and Logistics Acquisition Army Corrosion Executive Navy Corrosion Executive Air Force Corrosion Executive Director Corrosion Policy and Oversight Technical Staff Business Staff Logistics Research & Engineering Installations & Environment International Cooperation Working Integrated Product Teams Corrosion Policy, Processes, Procedures and Oversight Metrics, Impact, and Sustainment Science and Technology Outreach and Communications Facilities Training and Certification Specifications/Standard and Product Qualification OSD Joint Staff/J-4 Defense Logistics Agency Coast Guard IPT member representatives Army Navy Air Force Marine Corps Army Corps of Engineers General Services Administration National Aeronautics and Space Administration 7

8 Activities What We Do Policy Development and Implementation Weapon System and Major Facility Program Reviews Workforce Development Corrosion Metrics Collection and Analysis Specifications and Standards Outreach and Communications Science and Technology Project and Research Sponsorship Demonstration/Implementation Projects through Military Departments Technical Corrosion Collaboration

9 Policy Draft DoDI Operation of the Defense Acquisition System requires CPC planning for all systems (including MAIS, COTS, and GOTS) throughout the lifecycle..planning for and establishing 1) a management structure for CPC, and 2) the technical considerations and requirements in order to implement an effective CPC regime throughout the life cycle of a program. Planning documented in the Systems Engineering Plan and the Life Cycle Sustainment Plan DoDI Prevention and Mitigation of Corrosion on DoD Military Equipment and Infrastructure establishes structure of DoD Corrosion Program, responsibilities, and CPC planning procedures DoDD Maintenance of Military Materiel requires that corrosion prevention and control programs and preservation techniques be established throughout the system life cycle. 70% of sustainment costs are locked in by initial design

10 Oversight of Major Acquisition Programs

11 Workforce Development DAU CLM-038, Corrosion Prevention and Control Overview DAU CLE-070, Corrosion and Polymeric Coatings Web-based training modules ( Strategic partnership with NACE and SSPC delivering training to active duty military and government employees University of Akron BSc. in Corrosion Engineering University of Florida developed Distance Learning Course Aviation Focused Training - *** Coming Soon *** Maintainers Junior Engineers

12 Specifications and Standards Most corrosion-related specs and standards eliminated during acquisition reform in the 1990 s Causes corrosion requirements to be negotiated individually during acquisition Working with MilDeps to reestablish some needed Specs & Stds MIL-STD-1568C, Materials and Processes for Corrosion Prevention and Control in Aerospace Weapon Systems newly reinstituted as a Mil Std Supported by DI-MFFP-81403, Corrosion Prevention and Control Plan, and DI- MFFP-81402, Metal Finishes and Finishing Processes and Procedures (a.k.a. finish specification) MIL-STD-889, Dissimilar Metals Migrating some requirements to commercial standards Developing new standards with non-governmental standards bodies (e.g. SAE AS12500 Corrosion Prevention and Deterioration Control in Electronic Components and Assemblies) Joint SSPC-NACE Standard for CPC Planning

13 Outreach and Communication programmatic and technical information Biennial DoD - Allied Nations Technical Corrosion Conference August , Birmingham, AL Series of awareness videos for leadership and general public STEM Partnership with United States Naval Academy STEM Center Partnership with NACE and SSPC to provide corrosion content to Science Centers 13

14 Technology Demonstration/Implementation Projects Objective Implement mature corrosion control technologies in new and existing weapon systems and facilities Military Department-generated projects to qualify products and processes Demonstrate effectiveness in operational systems Update technical and logistics documentation

15 Elements of a Good Project Mission essential technology/methodology or significant mission enhancement Credible safety, readiness and logistics benefits Short implementation schedule Matching or complementary funds Significant return on investment Well-coordinated joint applicability Solid transition plan Ready for contract award ROI validation plan

16 TCC Technology Investment Categories Performance Prediction Assessment of Finish Surface Engineering Product Support Models Accelerated Testing Validation Design Tools Mechanical Properties Integrity Galvanic Interaction Degradation Mechanisms Mechanical Coating removal Substrate damage Adhesion Promotion Sacrificial Cleanliness Requirements Packaging/Storage Shelf-life Energy Maintenance

17 Level of Effort TCC Football Model Problem ID Research and Technology Development System Development/ Prototype Demonstration Universities Pitch Catch Implementation Government UCC TCC 17

18 S&T Investment Success TCC Activities (FY08-16) Papers Published 109 Student Involvement Undergrad/Grad 145 u / 99 g Service Academy Student Involvement 54 ~63% Transition Success Rate to Date! ROI = 16:1 CPC Projects by Category TCC is the Technical Corrosion Collaboration consisting of University, Service Academy, and DoD Laboratory collaborative S&T projects 18

19 Corrosion Planning and Implementation for DoD Systems and Equipment

20 CPC Planning During System Acquisition CPC performance has notoriously been traded for cost, schedule, and performance reasons during acquisition Why? Lack of awareness of and focus on long-term impacts No corrosion Key Performance Parameter Difficult to quantitatively measure long term corrosion performance with short term tests Increased corrosion performance often requires an investment (e.g. cost, weight, signature, etc.)

21 CPC Planning Best Practices Objective of a good CPC program is to maximize system availability and safety at the lowest cost not to produce a corrosion free system Investigate corrosion performance of legacy systems Establish a management process to review design decisions from a corrosion performance perspective Corrosion Prevention Team (CPAT; a.k.a CPAT, CPAB, CPAC, etc.) Involve subject matter experts There are often multiple solutions to a corrosion problem Bad decisions can have huge implications

22 CPC Planning Best Practices Consider corrosion performance early in the design phase Usage profile Materials selection Joining processes Coatings Geometries Storage Maintenance processes Require corrosion performance to be addressed in contracts

23 CPC in Sustainment Establish and follow a corrosion prevention and control program Utilize the DoD Labs for reach back support Consider the impact of deferring corrosion-related maintenance Require corrosion performance to be addressed in logistics efforts (depot maintenance, storage, etc) Make sure maintainers have the training and equipment needed

24 Corrosion Engineering Challenges Corrosion is a time-based phenomenon Accelerated corrosion tests are notoriously inaccurate Modeling and Simulation systems relating to quantitative prediction of corrosion are immature Corrosion is difficult to express as a performance parameter How is a corrosion failure defined? Under what type of testing? How long? Corrosion control products (coatings, CPC s, etc..) are often proprietary Procure using performance specifications where possible Corrosion is a multi-variable problem Opportunity for wide range of solutions

25 So Why Aren t We Doing Better?? Corrosion is rarely just a technical problem Prevent Detect Mitigate Manage Corrosion doesn t hurt today but it hurts tomorrow Easier to invest in corrective than preventive maintenance Hard to maintain leadership focus Corrosion is often a people problem Corrosion is a Leadership Issue Robert Herron Successful corrosion control requires Awareness and buy-in from leadership Teamwork between subject matter experts, designers, and maintainers Corrosion control is not the most important thing we do. Tools, training, and time for the personnel implementing the processes