Transfer of Pollution Prevention Technologies (2002) / Chapter Skim
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3. NDCEE Technology Transer: Selected Cases
3. NDCEE Technology Transer: Selected Cases
Pages 19-30
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ELECT kOCOAT AND CASE 11. POWDER COATING Waterborne Electrocoat technology~ase I is widely used in automotive, appliance, and general industrial metal coating applications.
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to facilitate the transition of electrocoat and powder coating technologies to both Department of Defense and defense industry applications.3 These two technologies were among the original project areas identified at the establishment of the NDCEE. The plan created by the NDCEE for transferring electrocoat and powder coating technology contained seven activities to meet the requirements of the statement of works 1} Establish baseline and identify requirements; 2)
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topics over the past 30 years. The minimum economic volume for electrocoat has been characterized as at least 2 or 3 million square feet per year of painted surface, or a significant percentage of the overall painted surface market.6 Based on its review of military procedures, industrial practices, and the overall program plan, the NDCEE installed an electrocoat and powder coating demonstration facility at the NDCEE's Johnstown location.
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installations implement appropriate technologies, the NDCEE's technology transfer effort includes: · Selection of coating materials, application techniques, and process parameters; · Testing of powder coat and electrocoat materials to military specification requirements; · Coating system design, configuration, and installation; and · Training for personnel who will operate a system, as well as on-site start-up assistance. .x Program Effectnreness Both powder coatings and electrocoat are relatively mature technologies in commercial applications.
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Utilizing these facilities, the NDCEE could perform its intermediary function with greater flexibility and impact than with its current dedicated bath. Powder Coat Powder coating is cited by the NDCEE as an example of successful technology transfer.'3 The NDCEE has assisted several facilities in investigating powder-coating technology for specific applications, including the Jacksonville Naval Air Depot (NADEP-JAX)
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In this case, the NDCEE was asked to investigate powder coatings specifically by the government contractor operating the ammunition production facility.20 The contractor stated this preference because other alternatives, such as dip coating, would require major changes to the production line, while powder coating could be easily retrofitted.24 A fourth issue is the use of existing military specifications and test methods by the NDCEE to validate coating quality. Although current military specifications sometimes call for the use of, for example, static corrosion tests (such as salt spray, also known as salt fog)
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Little data was available on the measured reduction of human exposures to toxic substances and the reduction of environmental pollution in using the powder coating process, which made the impacts of the NDCEE's powder coat program difficult to assess. The program appears to have one small-scale implementation, but adequate data to determine the cost-effectiveness of the program has not been assembled.
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Several clients have participated in this process, including the Corpus Christi Army Depot; the Naval Aviation Depot, Jacksonville; the Norfolk Naval Shipyard; the Puget Sound Naval Shipyard; and the Aberdeen Proving Ground.28 The NDCEE has also used the waterjet system to demonstrate the removal of coatings from jet engine parts, F-14 aircraft hook points, paint fixtures, artillery shells, military vehicles, and fragile surfaces used in submarine applications, as well as rubber removal from armored road wheels.29 1 FY94 1 FY95 1 :Y96 1 F`(97 1 FY98 I FY99 I .
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In the case of the wing fuel tanks of the KC-135, the mainstay of the Air Force tanker fleet, the varying surfaces of the tank limit such access. The Air Force has had little success in finding cleaning contractors that could meet time, cost, and performance guidelines for this task.38 Currently, contracting firms do much of the work on waterjet cleaning of surfaces.
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The process results in an improved coating compared to that obtained with regular physical vapor deposition. Both ion implantation and ion beam assisted deposition result in hard and very tenacious coatings that protect the surface of the coated material from wear and abrasion without adversely affecting the properties of the substrate.
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The following processing capabilities were specified: High-energy (up to 100 keV) ion implantation of gaseous species; Two low~nergy ion sources, operating at 1 keV and at 100 eV for ion beam assisted deposition in conjunction with a 4-hearth electron-beam evaporator, · Plasma source ion implantation system (option 1~; and · High-energy metal ion implantation system (option 2~.
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The effort focuses on the total cost of ownership, including the entire life-cycle cost of a system and extending to eventual disposal of the equipment. Ion beam treatments have a tremendous potential for success when life-cycle costs are considered.46 Concluding Remarks The definition phase of the NDCEE's ion beam surface modification program resulted in a very ambitious and complex design for the ion beam processing equipment.
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