Transcript 3 SERDP-ESTCP Overview for JTEG May 2016

SERDP-ESTCP Overview/
Weapons Systems and Platforms Efforts
Presented to JTEG Forum on Environmental Impacts and
Worker Safety
3 May 2016
Environmental Drivers
Reduction of Current and Future Liability
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Contamination from Past Practices
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Groundwater, Soils and
Sediments
Large UXO Liability
Emerging Contaminants
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Pollution Prevention to Control
● Life Cycle Costs
Elimination of Pollutants and
Hazardous Materials in
Manufacturing Maintenance
and Operations
Achieve Compliance Through
Pollution Prevention
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Environmental Drivers
Sustainability of Ranges, Facilities, and Operations
Maritime Sustainability
Threatened and Endangered Species
Toxic Air Emissions and Dust
Noise
UXO & Munitions
Constituents
Sustainable
FOB
Climate Change
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SERDP-ESTCP Project Locations/Orgs
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Program Area
Management Structure
Environmental
Restoration
Weapons Systems
& Platforms
Energy & Water
Resource Conservation
& Climate Change
Munitions
Response
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Strategic Goals
1.
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Reduce the Cost of Legacy Environmental Problems
Achieve Sustainability of Ranges and Operational Areas to meet
testing and Training Requirements and Environmental Obligations
Eliminate Hazardous Materials from Weapons Systems and
Platforms Maintenance and Manufacturing
Address DoD Requirements with Respect to Climate Change
Sustainable Operations of Deployed Forces
Goals Tightly Linked to DoD Requirements and Objectives
Quantitative Metrics and Specific Milestones Developed
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SERDP Investment Approach
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SERDP’s Investments Are Structured Through Annual
Statements of Need (SON)
● SON reflect:
♦ Longer term strategic plans to address high priority requirements
 Groundwater liability, live fire ranges, UXO, marine mammals and sonar,
eliminating Cr+6 etc.
 Issue-specific workshops form basis for strategic plans
♦ Increasing Focus on Sustainability and O&M Costs
 Success at reducing costs of legacy liabilities
 Need to reduce costs and long term vulnerability at installations and ranges
 Need to reduce life cycle costs of weapon systems
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ESTCP
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Environmental Security Technology Certification Program
Demonstrate innovative cost-effective environmental and
energy technologies
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Capitalize on past investments
 Transition technology out of the lab
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Promote implementation
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Facilitate regulatory acceptance
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Environmental Technology
Development Process
SERDP
ESTCP
Office of the Deputy Under Secretary of Defense – Energy Installations and Environment
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Management Process
Services’
Requirements
Statements
Of Need
SERDP Committees
• Army
• Navy
• Air Force
• DOE
• EPA
Open
Solicitation
R&D
Proposals
In-Progress
Reviews
Funded
Projects
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SERDP Technical Committees
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Members represent technical staff and research management from SERDP
Federal Partners
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Responsible for first level planning, review and development of program
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Provide significant time to SERDP
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Key to the effective execution of SERDP
Provide method for coordination across agencies
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Investment Approach
●
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SERDP’s Investments Are Structured Through Annual Statements of
Need (SON)
Longer term strategic plans to address high
priority requirements
♦ Groundwater liability, live fire ranges, UXO, marine
mammals and sonar, eliminating Cr+6 etc.
♦ Issue-specific workshops form basis for strategic plans
●
Focus on Sustainability and O&M Costs
♦ Reduce costs and long term vulnerability at
installations and ranges
♦ Reduce life cycle costs of weapon systems
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Responsive to evolving requirements

Emerging Contaminants
 Pb-free electronics
 Policy Goals
 Climate Change vulnerability and adaptation
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Weapons Systems and Platforms
• Manufacturing and Maintenance
- Green materials and processes
(principally related to surface
engineering technologies)
- Control and monitoring
(accelerated aging and field
demonstrations)
• Green Energetics
- New Materials
- Alternative Manufacturing
• Air and Noise Emissions
- Diesels and Gas Turbines
- Weapons and Munitions
- Ship and Industrial
Partnerships with Acquisition,
OEM, and
Maintenance Community
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SERDP/ESTCP Investments Related to
Corrosion
· DoD assets are subject to
significant degradation due
to corrosion, with specific
impacts in following areas
· Financial: $18-$22 billion
annually
· Readiness: Weapons systems
routinely out of commission
· Safety: Weapon systems
mishaps documented
· Many materials used to
impart corrosion resistance
have environmental and/or
worker safety concerns
SERDP and ESTCP Webinar Series (#29)
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Electrodeposition of Nanocrystalline Co-P Coatings
as a Hard Chrome Alternative
NAVAIR FRC SE
Jacksonville
Results
● nCoP meets the majority of acceptance criteria for coating quality, adhesion, fatigue,
corrosion, hydrogen embrittlement, fluid compatibility, wear, and impact testing.
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It is anticipated that nCoP may be widely specified per MIL-DTL-32502 as a hard
chrome alternative on the basis of testing completed to date.
Benefits
● Implementation will eliminate environmental and worker safety concerns associated
with the hexavalent chromium used in DoD plating operations.
Eliminating Chromium from
Medium Caliber Gun Barrels
Team: Benet Laboratories, Army Research Laboratory, Ares Inc.,
High Energy Metals, Inc., TPL, Inc., General Dynamics ATP
Results
 Process to explosively bond Tantalum-10%
tungsten liners to the insides of medium caliber
cannons.
 Firing tests demonstrated that the lined tube
showed superior wear resistance – lasts >three
times as long as chrome-plated tube.
Benefits
 Eliminates the use of hexavalent chromium in medium caliber gun
barrels while providing superior performance and reduced life cycle costs.
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Non-Chrome Primers – WP-201132
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NAVAIR PAX long term project to evaluate non-Cr primers
Evaluation of various new NC primer alternatives
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Latest info from Julia Russell, NAVAIR PAX ASETSDefense Workshop, Fort Myer 2014
PPG-DEFT 02-GN-084 Rare Earth NC primer authorized by NAVAIR over chromate
pretreats
H46 testing of NC system – Alodine T5900 RTU pretreat, Hentzen 17176KEP primer
NAVAIR has developed Al-rich primer as alternative to chromated primer on
aluminum, MIL-PRF-53022 primers on mixed metals and zinc-rich primers
on steel
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Initial test results look very promising
Al-rich primer 20 mos
KSC, with and without
topcoat
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Optimum Cadmium Alternative (WP201107), Hill AFB
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Data shows best alternative to Cd
is Al
Why not electroplated Al or IVD?
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Electroplates from toluene
Enclosed line, high capital cost
IVD vacuum process, uptime
problems
LHE ZnNi is taking over from Cd
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Why? ZnNi electroplates from
aqueous solution (just like Cd), so no
enclosed or vacuum line
Better performance than Cd
Not attacked by standard alkaline
cleaners
Works best with trivalent passivate
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Advanced Coatings Project
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Aim: Eliminate 90% Cd and Cr6+ from
depot maintenance in 5 years
Findings so far:

Evals of Tinker AFB, NADEP JAX, Letterkenny
AD
 Quantified all Cd and Cr6 usage
 Evaluated all processes
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Report recommendations and strategy
based on
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Impact to reduction targets
Impact to operations
Likelihood of adoption
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ESTCP Projects to Address Cr6+
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FY2000: Non-chromate Aluminum Pre-treatments (NAVAIR Pax River)
FY2005: Validation of Novel Electroactive Polymers as Environmentally
Compliant Coatings for Replacement of Hexavalent Chromium
Pretreatments (NAVAIR China Lake)
FY2006: Low Temperature Powder Coatings (Hill AFB)
FY2007: Joint DOD Demonstration and Validation of Magnesium Rich
Primer Coating Technology (NAVAIR Pax River)
FY2008: Ultraviolet Curable Powder Coatings (AFRL)
FY2008: Ultraviolet Curable Coatings for Aerospace Applications (Hill AFB)
FY2009: Validation/Demonstration of Anti-Corrosion Inhibitor Primer
Formulations as Replacements for Hexavalent Chromium Military Primer
Coatings (NAVAIR China Lake)
FY2009: Non-Chromate, ZVOC Coatings for Steel Substrates on Army and
Navy Aircraft and Ground Vehicles (ARL)
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Recent ESTCP Projects to Address Cr6+
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FY2010: Electrocoat Process for Non-Chromate Primers in DoD
Manufacturing (AFRL)
FY2011: Chromium Elimination and Cannon Life Extension (Benet Labs)
FY2011: Comprehensive Evaluation and Transition of Non-Chromated Paint
Primers (NAVAIR Pax River)
FY2012: Chrome Replacement for Gun Barrels (NAVSEA Dahlgren)
FY2013: Environmentally Friendly Fastener Coating Demonstration (PPG)
FY2013: Environmentally Friendly Zirconium Oxide Pretreatment (ARL)
FY2013: Improved Magnesium Protection for DoD Aviation and Weapon
Component Technology (ARL)
FY2015: Demonstration and Validation of Siloxane-Based Aircraft Topcoats
that are Isocyanate-Free and Provide a Reduced Environmental Impact
(NRL)
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Sources of Information
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All SERDP and ESTCP Project info is available at the Weapons Systems
and Platforms program area at https://www.serdp-estcp.org/ProgramAreas/Weapons-Systems-and-Platforms
Reports, Authorizations, Implementations, data on Coatings and Surface
Treatments are all available on the ASETSDefense Database at
Database for new HTML5-compatible browsers:
http://db2.asetsdefense.org/fmi/webd
Database, older browsers:
http://db.asetsdefense.org/Custom/customsearch.aspx
ASETSDefense Website (Workshop Briefings, general info on alternatives):
www.asetsdefense.org
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SERDP/ESTCP Initiative
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Numerous surface-engineering-related projects executed by SERDP, ESTCP
and other organizations to develop and evaluate new technologies that are
more environmentally friendly and reduce life-cycle costs
Problem is that stakeholders and weapons systems owners do not have
ready access to data to determine if new technology can be implemented
ASETSDefense is an initiative intended to develop information data bases
and organize workshops associated with technologies in the surface
engineering field; web site www.asetsdefense.org is entry point to
engineering data and materials selection data bases under development
Plans are being formulated to Host next ASETSDefense
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workshop December 5-7 2016 Shades of Green, Orlando, FL