1. F-15 Chrome Free Coating System 17 Jan 2018
Air Force Life Cycle
Management Center
F-15 Chrome Free Coating System 17 Jan 2018
Mr. Scott Vandersall
AFLCMC/WWQ
DSN:

2. Topics Background Depaint Process Current Paint System
F-15 Operating Locations
CTIO Ranking/Daytona Beach Testing
2014 F-15 Chrome Free Survey & Results
Findings Since Survey
Pricing Data
Way Ahead
CTIO – Coatings Technology Integration Office

3. Background Information
F-15 commenced non-chrome primer field service testing some 20 years ago
Two Tyndall a/c had right wings primed in 1997
Two more Tyndall aircraft primed in 2000
During evaluation, some corrosion and poor adhesion noted
Adhesion was attributed to poor surface prep
Formal lab testing of non-chrome systems completed in 2005 (UDRI )
Multiple surface preps, primers and topcoats evaluated
Deft 02-GN-084 showed most promise
First two Tyndall aircraft had Dexter Aerospace / Crown Metro Aerospace 10PW22-2/ECW 119 non-chrome primer applied to the right wings. Both had adhesion failures on titanium areas of lower wing and one had failures on aluminum lower outer wing. All areas required re-work.
Of the second two aircraft (right side only), one was primed with 10PW22-2/ECW 119 primer and the other had PRC EWAE 118 non-chrome primer applied. Adhesion failures were observed with EWAE 118 primer; possibly due to surface preparation issues.

4. Background Information
Painted first aircraft with full non-chrome system (RECC/02-GN-093) in Aug 2009
1-yr inspection performed at NO ANG
Coating outperformed existing system of similar age
No typical erosion/removal of paint at intakes and chipping around access panel screw holes
1 Yr
The pictures are of the same intake. The top one was during John Stephens’ 1-yr inspection. The one below was taken about 4 years 4 months after it was initially painted.
RECC – Rare Earth Conversion Coating
4 Yr, 4 Mo

5. Background Information
The full Non-Chrome system was approved for use on all F-15s in Jan 12
Received reports of chipped paint shortly after approval
Process issue not material
Process change was made in May 2012
.9 mil primer coat
Topcoat applied within 4 hours of primer application
Since process revision, no other field issues with the Cr-Free coatings reported

6. Depaint Process F-15 De-paint Process at Robins (B137) Timeline:
Tape/Prep, PMB, and clean-up Days
Tank blast and final wash - 1 Day
Prime & paint – 1 Day

7. Stack-up of DEFT/PPG RECC/02-GN-093 Non-Cr Coating System
Current Paint System
PREFERRED SYSTEM Used on the outer mold line on the USAF F-15C/D/E Fleet
Stack-up of DEFT/PPG RECC/02-GN-093 Non-Cr Coating System
Deft APC Topcoat
02-GN-093 Non-Cr Epoxy Polyamide Primer
Pretreatment: RECC 1015 Deoxidizer / RECC 3021 Non-Cr Conversion Coating
Substrate

8. Current Paint System
TOUCH UPS (Used on the outer mold line on USAF F-15C/D/E Fleet)
Stack-up of DEFT/PPG 02-GN-084 Coating System
Deft APC Topcoat
02-GN-084 Non-Cr Epoxy Polyamide Primer
Pretreatment: MIL-DTL-5541 (Alodine)
Substrate

9. Current Paint System
Stencil is incorrect: MIL-P-23377K was used with 02-GN MIL-P-23377N is used with 02-GN-093.

10. F-15 OPERATING LOCATIONS
Notes:
Total fleet worldwide, to include FMS: 1,069
USAF – 55% of total flee
Total USAF Fleet Size: 589
Total Bases: 16
Active: 9
ANG: 7
Total WGs/FWs: 17
Active: 10
Total MAJCOMs: 6
1. ACC (lead command)
2. USAFE
3. PACAF
4. AETC
5. AFMC
6. ANG
USAF Mission Design Series
F-15A-D: Air-to-Air
F-15E: Air-to-Ground
Foreign Military Sales – 45% of total fleet
(POC: Misty Turner)
Total FMS Jets: 482
FMS Customers: 5
1. Saudi Arabia (F-15S): C/D-81; S-70
2. Japan (F-15J): C (J)-157; D (DJ)-45
-- 14 FMS, 199 license-produced in Japan by MHI (One F-15C (J) will be excluded from the fleet for approx.3 years for extensive maintenance)
3. Israel (F-15I): A (20); B (6); C (17);
D (11); I (25)
4. Korea (F-15K): 39 (40 delivered; one loss) buying 40 (F-15K) (as of 8 Oct)
(First delivery occurred 7 Oct 05)
Direct commercial sale-deliveries
5. Singapore:
Congressional notification 22 Aug 05
Direct commercial sale
Value: $741M
Signed by Boeing & Singapore Dec 05
12 aircraft with option for 8 more. Oct 07 option for 8 was exercised and order was placed for 4 additional A/C which brings their total to 24 A/C.
Singapore signed the LOA 24 Feb 06
Deliveries began in 2009
Managed by 912 AESG (WPAFB). Sustainment managed by 830 ACSG.
8 aircraft delivered--will reside at 428 FS, Mt. Home AFB for 1 year
Chart OPR: Pam Ochoa, 568 ACSS/GFLA, ; Data Source: EMAP
USAFE-76 aircraft (17%)
48 FW LAKENHEATH (F-15C-19, F-15D-2, F-15E-55)
AFMC-7 aircraft (2%)
96 TW EGLIN (F-15C-2, F-15E-5)
ACC-179 aircraft (40%)
366 FW MT HOME (F-15E-47)
4 FW SEYMOUR (F-15E-94)
53 WG EGLIN (F-15C-5,F-15E-1)
53 WG(T) NELLIS (F-15C-5,F-15D-1,F-15E-7)
57 WG NELLIS (F-15C-8,F-15D-2,F-15E-9)
ANG-137 aircraft (30%)
104 FW BARNES (F-15C-20,F-15D-1)
125 FW JACKSONVILLE (F-15C-20,F-15D-1)
142 FW PORTLAND (F-15C-20,F-15D-1)
144 FW FRESNO (F-15C-20,F-15D-1)
159 FW NEW ORLEANS (F-15C-20,F-15D-1)
173 FW KINGSLEY FIELD (F-15C-23,F-15D-9)
PACAF-54 aircraft (12%)
18 WG KADENA (F-15C-50,F-15D-4)
USAF Totals (46%)
F-15C = 212
F-15D = 23
F-15E = 218
453
C/D Fleet ANG 58% - AD 42%
Total USAF F-15 Fleet: 453 10

11. CTIO’s Ranking of Coating Systems for Corrosion Resistance
1. Alodine 1600/02Y040/99GY001 – Old USAF Control
2. PreKote/ AE2100 (Mg Rich Primer)/DEFT 99GY001
3. PreKote/ AE2100 (Mg Rich Primer)/AE 5000
4. AC131(BoeGel)/ AE2100 (Mg Rich Primer)/AE 5000
5. EAP9 (BoeGel)/PRC CA7236 (MgO Primer)/PRC CA 9311
6. PreKote/02Y040/99GY001 – Current USAF Control
7. Alodine 5200/Hentzen 53055GEP/Hentzen35515 APX
8. AC131(BoeGel)/ AE2111 (MgO Primer)/AE 5000
9. DEFT RECC/DEFT 02GN097/DEFT 99GY001
10. DEFT RECC/DEFT 02GN093/DEFT 99GY001 - F-15 System
Best
Worst
This table was taken directly from an AFRL presentation on Cr-Free Coating Systems Characterization/Qualification and Recommendations dated 14 Jan 14. The presentation compared several non-chrome systems with chrome systems for the purpose of qualifying systems to MIL-PRF At the time of the presentation no system could qualify. F-15 System (RECC/02GN093) performed worst.
Chrome
Non-Chrome
Based on outdoor exposure testing at the Daytona Beach site
This table prompted the initiation of the chrome free survey.

12. Chrome Free Survey Survey released in January 2014
Three main questions asked on the survey
Do you scuff sand and over coat at mid cycle?
Have there been any unusual problems?
Has there been any unusual instances of corrosion on the outer mold line?
Answers were generally positive

13. Chrome Free Survey Results
Only a couple of ANG bases performed scuff sand & overcoat at mid cycle as Standard Operating Procedure
No unusual paint problems
Most reported problems were on aircraft painted before the process was fixed
All other problems were typical leading edge paint erosion
No unusual corrosion was reported on the outer mold line

14. Findings Since Survey Wet spots on paint complaints occurred
2015 survey results proved it to be a non-issue
Majority of F-15 corrosion found in fuel tanks
Small percentage of engineering requests are for F-15 corrosion-related assistance
From January 2011 to April 2017, only 2% of 202’s were corrosion-related, for the same period the only 0.4% of 107’s and ETARs were corrosion-related.
There were 34 corrosion-related 107s/ETARs from 2011 to Apr 2017, total number of 107s/ETARs for that period was 7,642.
There were 462 corrosion-related 202s from 2011 to Apr 2017, total number of 202s for that period was 23,720.

15. Pricing Data Non-Chrome System - $177.37/gallon
Product
Nomenclature
Size
Cost
Comments
RECC 1015
Non-Chrome Deoxidizer
1 Gallon
$32.37
Current TO requirements
5 Gallons
$158.18
50 Gallons
$1,262.77
RECC 3021
Conversion Coating
$272.46
$2,780.63
02GN093
Non-Chrome Primer
$96.50
AMS 1640
Acid Etch Solution
55 Gallons
$440.67
Cost of old chrome system
MIL-DTL-5541F
Alodine
60 LB Bag $
MIL-PRF-23377, TYPE 1, CLASS C2
Chrome Epoxy Primer
$47.00
6.3 Lbs powder Alodine makes 100 gallons of solution – ($ ((60/6.3 )*100))= $2.95/gal
Acid Etch Solution – $440.67/55 = $8.01/gal
Non-Chrome System - $177.37/gallon
Chrome System - $57.96/gallon
Although Non-Chrome system is more expensive per gallon, one gallon of the non-chrome system will cover a larger area due to thinner primer coats required to prevent peeling

16. Way Ahead Continue 6 year paint cycle
Qualification of other combinations of paint system
Welcomed!
Likely to require on-aircraft use for complete comprehensive evaluation
Based on CTIO results, lab testing alone may not provide clear indication of pass/fail.

17. QUESTIONS?