SBIR-STTR Award

Chemical stripping solution processes are used at Tinker AFB, and other repair depots, to remove specialty coatings such as zinc-nickel plating, chrome plating, etc. For the majority of the stripping processes, the chemistry is defined in the Technical Orders. However, the Technical Orders do not provide process parameter information or guidance on operation of the stripping processes. Research of the stripping processes is required to optimize the stripping rate to decrease flow days and increase life of part through minimizing part time in solution. During Phase I, ES3 will perform research on the stripping processes employed at Tinker AFB. The research will seek to understand key process variables that have an effect on time and cost to the stripping operation. The research will define the best methods to establish metal build-up limits that would then be used to determine when it is most cost effective to continue processing with a stripping solution versus replacing the solution. A test plan will be developed that provides the concept and methodology for optimization and cost reduction of the stripping processes. ES3 will demonstrate and validate the test plan by determining stripping efficiency as a function of metal build-up level, for one stripping process.

Benefits:
ES3 anticipates the results of Phase I work will validate the feasibility and need for immediate pursuit of Phase II efforts for multiple stripping solutions utilized at Tinker AFB. After successful Phase II testing, development and implementation of the optimized stripping processes at the Tinker AFB repair depot, the immediate benefit will be reduced shop operational costs. An estimate of the annual savings will be determined in Phase I. The reduced shop operational costs will occur as a result of: A) Higher throughput, B) Reduced re-processing, C) Reduced flow days, D) Improved effectiveness of the stripping systems, E) More effective use of engineering support (through statistical process control), and F) Reduced part or substrate damage. These process improvements will be applicable to both military and commercial repair facilities that utilize coating removal processes

Keywords:
Coating removal, chemical stripping, process optimization, reduced flow days

The USAF repair depots expend tremendous amounts of resources applying high technology thermal spray coatings to improve the performance of components and systems. In general, thermal spray application processes are complex, requires high cost equipment that are expensive to operate, need highly trained personnel and necessitate constant verification testing to ascertain the coatings meet requirements. The engineering and maintenance personnel must utilize multiple systems, databases and data inputs to keep the equipment operating at levels required to maintain the highest quality coating standards. The Thermal Spray Dashboard system integrates the various independent thermal spray process data in such a way that it can be interpreted, analyzed and utilized to assist process engineering and production personnel in their task of ensuring an efficient, consistent process is maintained that delivers high quality coating products. The ultimate benefit will be improved performance and reduced overall operational costs. The reduced operational cost will occur as a result of: higher throughput, reduced rework, reduced flow days (result of reduced rework and reduced lab delays), reduced metallurgical laboratory testing, reduced consumable material cost, greater reliability & reduced maintenance of equipment and reduced engineering support.