Major Dan Bullock Chief, AF Corrosion Prevention and Control Office 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 Recommendations and conclusions 2

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 2

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 2

Survey Areas Aircraft Maintenance Environmental Management Plans & Scheduling Quality Assurance Training 5

PROGRAMMATIC FINDINGS 1

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 8

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) 8

TECHNICAL FINDINGS 1

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 19

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 8

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 8

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 10

Other Maintenance Activities No Significant issues found in: Avionics Munitions Communications/Electronics Pneudraulics 15

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 11

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 13

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 8

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 15

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) 21