Integrity  Service  Excellence Going Green – Embracing Environmentally Friendly Technologies for Tomorrow Colonel Paul C. Waugh Director of Propulsion 03 Sep 09 Air Force Materiel Command 1

Propulsion Environmental Working Group 2 AF Director of Propulsion Collaboration for Advanced New Sustainment Insertion

3 PEWG Vision The Ultimate Green Engine A gas turbine engine designed and built so that the parts do not corrode or wear out during the period the engine is deployed. The engine contains no toxic materials, components and no hazardous substances are used/released during manufacturing, maintenance, repair, and overhaul of the engine. Engine operation should have minimal environmental impacts from noise and air emissions. Finally, valuable components and/or materials are recovered when the use period ends. Otha Davenport 1999

4 PEWG Mission Work across Propulsion Industrial Base (PIB) to discover and insert safe, clean and effective manufacturing, maintenance, repair and overhaul (MRO) technologies –Performance: Increase Time On Wing –Affordability: Insert new engine technology into fielded engines –Competiveness: Infuse new technologies into DoD depots & weapon systems

PEWG = Pollution Prevention (P2) Pollution prevention is reduction or elimination of pollution at the source instead of at the end-of-the-pipe or stack Versus Environmental Management which is compliance with laws and making the operation manageable 5

6 Obstacles to P2 “Hard Sell” because benefits in distant future Optional Focus technology awareness versus insertion Neither amicable to industry interest nor a sources of innovation Mission Impossible

7 PEWG Collaboration Simple concept – organize and coordinate a PIB attack on environmental security and weapon system sustainment problems –PEWG is a mandated AF working group –Organized under the DoD Joint Propulsion Coordinating Committee (JPCC) –Reporting directly to the AF Director of Propulsion Assess PIB environmental issues Build technical & financial networks

PEWG Network 8

9 Stakeholders PEWG Network JALC DoD Labs SPD/SM KC-135 B-52 Army DSCR NATO- RTO/AVT 76MXW PEWG = DOP HazMat Management Subcommittee Industry (OEMs/Vendors) 309MXW DLA JPCC Fed Labs ESTCP SAF/IA HQ AFMC/A5S/A4M PSTWG & MRO&P HLS HLS Navy

10 Funding Sources DoD Investments –OC-ALC, OO-ALC, ASC/ENV (GOCOs) –ESTEP, SERDP –FCT, DACP, STP, RTOC, SBIR, QRFP, S3C PMDs of military organizations –Acquisition Programs –MRO organizations (DoD depots & FRCs) –P2 Programs Industry, Federal and State cost sharing Congressional adds LeveragingLeveraging

11 Bridging Technology “Ditch” Technology Ditch TRL 6 TRL 7 Plating - NLOS Cr6 Coatings – LOS & NLOS Solvents Old Dry Sprays HVOF SPD Lasers Net Shaping Cladding Peening Welding 0 Cr6 Coatings CERAL 3450 ODS Free Benign Solvents New

12 Obtain buy-in –Cognizant weapon system, product and process engineers –Funding source(s) –Program Manager(s) Fielded MRO operations –Maintenance practices –Repair methods –Overhaul process New engine & component manufacturing –Component design –Industrial process Implementation Approch

13 AFMC Current Projects 76 PMXG/QP & 639 ACSG/EN Qualify Advanced Powder Coating Powders –Vanes Qualify HVOF Coating Removal System –15 engine components Qualify Supersonic Particle Deposition –Magnesium Gear Boxes (continued)

14 76 PMXG/QP & 639 ACSG/EN Develop requirements documents and specifications 10 & 13 meter Test Cell complex –Bio fuels –Stronger building materials (concrete) –Noise reduction 60db 327 ASW/YP Strategic Materiel Recovery & Reuse Project –2 year “Proof of Concept” –Closed loop de-manufacturing process using field scrap –Institutionalize AFMC Current Projects

15 AFMC Current Projects SAF/IAP - Foreign Comparative Testing (FCT) Qualify CERAL 3450 –Replace SermeTel W (Cr6) Qualify Environmentally Controlled Coating Application Modules –Humidity & temperature, heat treat –Replaces open air spray booths Qualify portable Hand Held Laser Welding –One time ABDR field level fixes –Replaces TIG welding Qualify Advanced Plasma Spray Equipment –Triple Anode Axial feed system –Reduces material waste, increases efficiency (continued)

16 AFMC Current Project Congressional Line items Qualify non-hazardous Super Alloy Coatings –Engines, Landing Gear, Actuators, Structural Components –Reduces weight –Reduces chrome plating (CR6) –Increases durability (Continued)

17 Suggested Need Areas Advanced “NLOS” spray technologies to replace tank based processes Radiological coating disposal methodology Non-Radiological thermal barrier coating to eliminate thorium Transportable waste-to-energy equipment (continued)

Suggested Need Areas Laser additive manufacturing technologies Coating removal processes w/out HAZWASTE DoD Strategic Material Recovery and Reuse closed-loop de-manufacturing processes 18

19 Guidance for PEWG Projects Present evidence that project is TRL & MRL 7+ Indentify specific components that benefit Identify specific benefits that will accrue Provide information required by source of project funds Nominate by contacting PEWG Program Manager Present your science at Summer PEWG meetings

Food for Thought A vision without a task is a dream A task without a vision is drudgery. But a vision with a task can change the world. ---Black Elk A vision without a strategy is a prescription for failure A vision without action is called a daydream; but then again, action without a vision is called a nightmare. ---Jim Sorenson 20

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