Combat Rescue Helicopter (CRH) Non-Chromium Implementation 17 Jan 18 USAF Non-Chrome TIM Gene McKinley CRH Program, AFLCMC/WIH Helicopter Program Office, WPAFB (937) 713-0280 gene.mckinley@us.af.mil Distribution A: Approved for Public Release; Distribution Unlimited Case 88ABW-2017-4593

CRH Program Overview Sikorsky Aircraft Company (SAC) awarded contract for 112 HH-60W aircraft on June 2014 to support USAF combat search and rescue mission CRH designated as HH-60W and is baselined from a UH-60M Army “Blackhawk” SRR/SFR April 2015 PDR April 2016 CDR May 2017 Flight test projected to start 4th Qtr 2018 Required Asset Availability (RAA) planned for 1st Qtr 2020 Distribution A: Approved for Public Release; Distribution Unlimited Case 88ABW-2017-4593

Program Office Non-Chromium Use Implementation (Aug 2014) Requirement Assessment USAF specification SAC proposal (Oct 2014) ESOH WG Discussions System Safety Low 882E Risk (Dec 2014) ACC Requested AFRL assessment USAF Corrosion office assessment (CPCO) (Feb 2015) More Data SAC completed field testing Army AED accepted ECP 2 additional NAVAIR reports (Mar 2015) AFRL/USAF CPCO Risk Assessment Low risk exterior Medium risk interior Primer qualified over Chromate Conversion Coating (CCC) Coordination with Warner Robins WIU Chief Engineer (CE) Assessment Concurred pending CRH inspection requirements (Apr 2015) ESOH WG Discussions Corrosion risk Army implementation plan (Aug 2015) Integrated Risk Assessment Medium Program Risk Accepted by SPM (Oct 2015) Approve ECP System Spec Change Approve the use of Non-chromium primer on Interior and Exterior of CRH Continue Tracking through Logistics, R&M, and ESOH WG Distribution A: Approved for Public Release; Distribution Unlimited Case 88ABW-2017-4593

Legacy HH-60G Current USAF Fleet is aging HH-60G T.O. 1-1-8 Primer (Aug 2014) Requirement Assessment USAF specification SAC proposal Primers Definition: Type I - Standard pigments Class C1 - Barium chromate based corrosion inhibitors Class N - Non-chromate based corrosion inhibitors MIL-PRF-23377 - Solvent-borne primer MIL-PRF-85582 - Waterborne primer Current USAF Fleet is aging HH-60G T.O. 1-1-8 Primer Exterior primer coated with (1) coat of MIL-PRF-23377J Type I, Class C1 epoxy Interior primer coated with one (1) coat of MIL-PRF-23377J Type I, Class C1 epoxy or MIL-PRF-85582D, Type I, Class C2 epoxy. Topcoat Exterior painted with two (2) coats of dark gray (FED-STD-595C/36118) MIL- PRF-85285E Type I polyurethane (high solids). Cockpit painted with two (2) coats of dull black (FED-STD-595C/37038) MIL- PRF-85285E Type I polyurethane (high solids). Cabin interior, unless otherwise specified, shall be painted with two (2) coats of dark dull gray (FED-STD-595C/36320) MIL-PRF-85285E Type I polyurethane (high solids). Distribution A: Approved for Public Release; Distribution Unlimited Case 88ABW-2017-4593

SAC Proposed Non-Chrome Solution (Aug 2014) Requirement Assessment USAF specification SAC proposal Primers Definition: Type I - Standard pigments Class C1 - Barium chromate based corrosion inhibitors Class N - Non-chromate based corrosion inhibitors MIL-PRF-23377 - Solvent-borne primer MIL-PRF-85582 - Waterborne primer Exterior HH-60W Proposed MIL-PRF-85285 MIL-PRF-23377 Type I Class N BSAA / Alodine T5900 reactivation* Clad Aluminum 7075-T6 MIL-PRF-85285E Type IV Class H polyurethane (high solids) Topcoat (Dull gray FED-STD-595C/36320 Dull black FED-STD-595C/37038) Various vendors MIL-PRF-23377J(2) Type I Class N epoxy Primer (PPG 02-GN-084) MIL-DTL-5541 Tri-chromium based conversion coating for surface reactivation (Henkel Alodine T5900) MIL-A-8625 Type IC Boric Sulfuric Acid Anodized (BSAA) MIL-DTL-85054 Corrosion Inhibiting Compound (Cor Ban 35) Interior HH-60W Proposed Anodize Processes: Boric Sulfuric Acid Anodize (BSAA) Thin Film Sulfuric Acid Anodize (TFSAA) also MIL-A-8625 Type IIB Tartaric Sulfuric Acid Anodize (TSAA) MIL-PRF-85285 MIL-DTL-85054 MIL-PRF-23377 Type I Class N BSAA / Alodine T5900 reactivation* Clad Aluminum 7075-T6 Distribution A: Approved for Public Release; Distribution Unlimited Case 88ABW-2017-4593

Exterior HH-60W Proposed (Dec 2014) ACC Request AFRL assessment USAF Corrosion office assessment Exterior – Assessment Exterior HH-60W Proposed Primers Definition: Type I - Standard pigments Class C1 - Barium chromate based corrosion inhibitors Class N - Non-chromate based corrosion inhibitors MIL-PRF-23377 - Solvent-borne primer MIL-PRF-85582 - Waterborne primer MIL-PRF-85285 MIL-PRF-23377 Type I Class N BSAA / Alodine T5900 reactivation* Clad Aluminum 7075-T6 MIL-PRF-23377J(2) Type I Class N epoxy Primer - PPG 02-GN-084 US Navy has decided NOT to implement change because production is ending US Army depot has been using the same materials above on the external airframe [with the exception of using CARC as the topcoat] since 2008. Sikorsky has sent ECPs to the US Army to implement non-chromated primer on the Outer and Inner Mold Line (OML and IML) for production aircraft The US Army has identified that they will soon transition to this coating stack-up for production aircraft US Air Force has evaluated this coating system but has not implemented on any weapon system as proposed January 2019, around “W” production time, Class C1 primer material expected to be banned for use in the European Union and other countries with similar laws. Distribution A: Approved for Public Release; Distribution Unlimited Case 88ABW-2017-4593

Interior HH-60W Proposed Interior - Assessment (Dec 2014) ACC Requested AFRL assessment USAF Corrosion office assessment Interior HH-60W Proposed Same proposed coating system as on Exterior Same Primer Additional CorBan 35 MIL-PRF-85285 MIL-DTL-85054 MIL-PRF-23377 Type I Class N BSAA / Alodine T5900 reactivation* Clad Aluminum 7075-T6 MIL-PRF-23377J(2) Type I Class N epoxy Primer - PPG 02-GN-084 US Navy has decided NOT to implement change because production is ending Army Aviation Engineering Directorate in process of agreeing to accept SAC’s transition plan to non-chrome interiors - Class 2 change to non-chrome interiors US Air Force has not implemented on any weapon system as proposed US Army and US Air Force production aircraft are facing EU legislation banning Hexavalent Chromium – further supports commonality between UH-60M and HH-60W Distribution A: Approved for Public Release; Distribution Unlimited Case 88ABW-2017-4593

Sikorsky Testing (Dec 2014) ACC Requested AFRL assessment USAF Corrosion office assessment Tested in lab tests and in various airframe components of the IML for Navy MH-60 field evaluations Lab testing indicates type I non-Cr6+ primer had better adhesion than baseline Cr6+ with equivalent corrosion performance Field evaluation of 8 aircraft-no corrosion or adhesion loss observed on any of the components with the MIL-PRF-23377 Type I Class N primer after 1500 flight hours (~4years) Galvanic corrosion – non-Cr6+ primer performed equivalent to the Cr6+ baseline; validates lab tests Lab tests indicate the non- Cr6+ primers perform better over non- Cr6+ conversion coatings; identified as possible adhesion issues Distribution A: Approved for Public Release; Distribution Unlimited Case 88ABW-2017-4593

Sikorsky Testing (Dec 2014) ACC Requested AFRL assessment USAF Corrosion office assessment HH-60G Proposed HH-60W Corrosion Protection Chromic acid anodize Boric sulfuric acid anodize Equivalent Alodine 1200 Alodine T5900 MIL-PRF-85582 Class C1 or C2 MIL-PRF-23377 Class N Limited MIL-PRF-85285 clear coat MIL-PRF-85285 clear coat Improved Sealant AMS 3265 Corrosion inhibiting sealant Limited wet install of fasteners Wet install of fasteners Limited fluid film fog Cor Ban 35 AV-Dec gaskets 85582-I-C1 85582-II-C1 23377-I-N 23377-II-N Distribution A: Approved for Public Release; Distribution Unlimited Case 88ABW-2017-4593

USAF/Lockheed Martin Evaluations (Dec 2014) ACC Requested AFRL assessment USAF Corrosion office assessment C-130J Lab testing of tri chrome pretreatments (TCP) over thin film sulfuric acid anodized (TFSAA) indicates corrosion performance equivalent to chromate control Lockheed Martin reports use of BSAA instead of TFSAA should have no impact to corrosion performance Lab testing of PPG 02-GN-084 over TFSAA has equivalent or better adhesion and corrosion performance when compared to chromate control “low chrome” systems performed no better than non-chrome systems Validation testing for PPG 02-GN-084 primer indicated the manufacturer skipped necessary induction time requirements, leading to poor adhesion F-22 uses a BSAA seal and is lab testing PPG 02-GN-084 as well as 3 others for IML use; Currently using PPG 44-GN-098 (NCr epoxy primer) on OML Distribution A: Approved for Public Release; Distribution Unlimited Case 88ABW-2017-4593

Navy Testing NAS PAX River (Feb 2015) More Data SAC completed field testing Army AED accepted ECP 2 additional NAVAIR reports 2024 Aluminum Scale 1.0 - 5.0 qualitative Anodized with 23377 Type I Cl N – 1.0 Anodized with Chrome Primer – 0.5 CCC with 23377 Type I Cl N – 1.0 CCC with Chrome primer – 0.0 Sikorsky Proposed Distribution A: Approved for Public Release; Distribution Unlimited Case 88ABW-2017-4593

Navy Testing NAS PAX River (Feb 2015) More Data SAC completed field testing Army AED accepted ECP 2 additional NAVAIR reports 7075 Aluminum Scale 1.0 - 5.0 qualitative Anodized with 23377 Type I Cl N – 1.0 Anodized with Chrome Primer – 0.0 CCC with 23377 Type I Cl N – 1.2 CCC with Chrome primer – 0.0 Sikorsky Proposed Distribution A: Approved for Public Release; Distribution Unlimited Case 88ABW-2017-4593

Navy Testing NAS PAX River (Feb 2015) More Data SAC completed field testing Army AED accepted ECP 2 additional NAVAIR reports Alodine 1200S (CCC) and BSAA were the best performing surface treatments with BSAA slightly outperforming Alodine 1200S PreKote and BoeGel were the worst performers and not recommended for US Navy or Marine Corp Chromated Primers (solvent-borne and water-reducible) were the best performers followed by PPG 084 All Primers are centered close to the mean undercut rating Distribution A: Approved for Public Release; Distribution Unlimited Case 88ABW-2017-4593

AFRL/CPCO Risk Assessment (Mar 2015) AFRL/USAF CPCO Risk Assessment Low risk exterior Medium risk interior Primer qualified over Chromate Conversion Coating (CCC) PPG Non-Cr primer qualified over CCC (not BSAA) Recommend Sikorsky wet install fasteners because Machined surfaces no longer have BSAA Fasteners dissimilar metals Exterior coatings can be repaired easily when damage is visually identified; low risk of increased corrosion Interior coatings can be inaccessible and can remain on the interior surfaces for the life of the system; medium risk of increased corrosion. Undetected damage can impact availability and drive extensive maintenance costs Distribution A: Approved for Public Release; Distribution Unlimited Case 88ABW-2017-4593

CRH Program Risk HH-60W Program Risk Generated and Accepted by SPM (Aug 2015) Integrated Risk Assessment Medium Program Risk Accepted by SPM HH-60W Program Risk Generated and Accepted by SPM If corrosion on the aircraft interior occurs with the use of non-chromated coatings, then increased maintenance cost could occur Risk Closure criteria: no change in performance compared to HH-60G (Legacy) Distribution A: Approved for Public Release; Distribution Unlimited Case 88ABW-2017-4593

CRH APPROVAL (Oct 2015) Approve ECP System Spec Change Approve the use of Non-chromium primer on Interior and Exterior of CRH HH-60W 1st USAF platform to approve the use of complete Non-chromium coating system stackup for Interior airframe CRH System Specification changed Expect to carry moderate Program/Airworthiness risk until enough field data verifies assessment results (~2025) Annual Corrosion Prevention Advisory Board to oversee performance under the purview of Aircraft Structural Integrity Program Distribution A: Approved for Public Release; Distribution Unlimited Case 88ABW-2017-4593

QUESTIONS Thank You Helicopter Program Office POCs: - ESOH: Gene McKinley (937) 713-0280 gene.mckinley@us.af.mil - Corrosion: Luis Diaz-Rodriguez (937) 713-0248 luis.diazrodriguez.1@us.af.mil Distribution A: Approved for Public Release; Distribution Unlimited Case 88ABW-2017-4593