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UV Curable Powder Coatings for Aerospace Applications ESTCP Project WP-0801 Presenter: Christopher Geib [email_address] Sc...
Abstract <ul><li>Temperature sensitive substrates such as aluminum and magnesium are used in the manufacture and sustainme...
Outline <ul><li>Powder Coating Overview </li></ul><ul><li>UV-Curable Powder Coatings Overview </li></ul><ul><li>Robotics a...
Powder Coating Overview <ul><li>Today these are no longer limitations! </li></ul><ul><li>Previous ways of thinking about p...
<ul><li>Modern powder coatings are: </li></ul><ul><ul><li>Lower temperature cures (~ 250°F or less) </li></ul></ul><ul><ul...
Powder Coating Overview <ul><li>Advantages of powder coating: </li></ul><ul><ul><li>Elimination of volatile organics (VOC)...
<ul><li>A UV-cure powder coating is generally an acrylated polymer </li></ul><ul><li>Melts at low temperatures </li></ul><...
<ul><li>Decrease in thermal exposure. </li></ul><ul><li>Large bulky parts that cannot fit into existing ovens can be coate...
<ul><li>UV-cure powder requires less energy because the energy is focused to a specific part only as long as needed. </li>...
<ul><li>Why Use Robots? </li></ul>Robotics as an Aid to Curing Distribution A. Approved for public release; distribution u...
Robotics as an Aid to Curing Daimler-Chrysler Ulm, Germany Cleveland, Ohio Test Lab Development and use of robots for curi...
Light tunnel approach using various size  UV lamps to optimize cost and exposure   Robotics as an Aid to Curing Distributi...
<ul><li>High Capital Cost </li></ul><ul><ul><ul><ul><li>Lamps, cooling, fixtures, integration </li></ul></ul></ul></ul><ul...
Robotics as an Aid to Curing <ul><li>Robots ensure repeatability </li></ul><ul><li>Robots with UV sources can maintain ext...
Tools have been designed to facilitate offline simulation of robotic UV curing.  These tools allow for rapid path developm...
ESTCP Project WP-0801 <ul><li>The Problem: </li></ul><ul><ul><li>DoD spends millions of dollars annually on solvent-based ...
<ul><li>Objectives: </li></ul><ul><ul><li>Demonstrate a VOC/HAP-free, Ultraviolet cure powder coating on DoD   hardware </...
<ul><li>Requirements of a UV-cure powder for military use: </li></ul><ul><ul><li>Must perform at least as good as MIL-PRF-...
<ul><li>Typical Applications for UV-Cure Powder: </li></ul>ESTCP Project WP-0801 Aircraft components Distribution A. Appro...
ESTCP Project WP-0801 Aircraft Distribution A. Approved for public release; distribution unlimited.  AFMC 88 ABW/PA Case N...
ESTCP Project WP-0801 Aerospace Ground Support Equipment Distribution A. Approved for public release; distribution unlimit...
<ul><li>Powders: </li></ul><ul><ul><li>Currently considering two powders </li></ul></ul><ul><ul><li>Both in gloss white, s...
<ul><li>Possible future follow on efforts include marine applications. </li></ul>ESTCP Project WP-0801
<ul><li>Milestones </li></ul><ul><ul><li>Joint Test Protocol submitted Sept 2008 </li></ul></ul><ul><ul><li>Robot acquired...
ESTCP Project WP-0801 Thank you! Points of contact for UV-curable Powder Coatings ESTCP Project WP-0801: Mr. Corey Q. Blis...
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UVCPC WP 0801 Nasa 2008

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This is a copy of my presentation at a NASA seminar regarding my UV Cure Powder project.

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  • Transcript of "UVCPC WP 0801 Nasa 2008"

    1. 1. UV Curable Powder Coatings for Aerospace Applications ESTCP Project WP-0801 Presenter: Christopher Geib [email_address] Science Applications International Corporation (SAIC) Presented at: The C3P and NASA Technical Workshop UC San Diego, San Diego, CA 18 – 20 November 2008 Distribution A. Approved for public release; distribution unlimited. AFMC 88 ABW/PA Case Number: WPAFB 08-4512
    2. 2. Abstract <ul><li>Temperature sensitive substrates such as aluminum and magnesium are used in the manufacture and sustainment of weapon systems and ground support equipment. This project will demonstrate, validate and successfully implement a VOC/HAP-free, UV-cure powder coating on DoD depot production hardware to replace solvent-borne organic coatings. The project will utilize both existing and new UV-curable powders in a side-by-side demonstration with the current existing wet paint system. The use of state-of-the-art-robotics will also be demonstrated. </li></ul>Distribution A. Approved for public release; distribution unlimited. AFMC 88 ABW/PA Case Number: WPAFB 08-4512
    3. 3. Outline <ul><li>Powder Coating Overview </li></ul><ul><li>UV-Curable Powder Coatings Overview </li></ul><ul><li>Robotics as an aid to Curing </li></ul><ul><li>ESTCP Project WP-0801 </li></ul>Distribution A. Approved for public release; distribution unlimited. AFMC 88 ABW/PA Case Number: WPAFB 08-4512
    4. 4. Powder Coating Overview <ul><li>Today these are no longer limitations! </li></ul><ul><li>Previous ways of thinking about powder: </li></ul><ul><ul><li>Coating cure temperatures – typically above 428°F </li></ul></ul><ul><ul><li>Prohibitive for use on tempered metals (Al, Mg, Ti) </li></ul></ul><ul><ul><li>Prohibitive to use on composites </li></ul></ul><ul><ul><li>Powder coatings were designed as barrier protection </li></ul></ul>Distribution A. Approved for public release; distribution unlimited. AFMC 88 ABW/PA Case Number: 08-3215
    5. 5. <ul><li>Modern powder coatings are: </li></ul><ul><ul><li>Lower temperature cures (~ 250°F or less) </li></ul></ul><ul><ul><li>UV or EB cure added </li></ul></ul><ul><ul><li>Inhibitor packages available </li></ul></ul>Powder Coating Overview Distribution A. Approved for public release; distribution unlimited. AFMC 88 ABW/PA Case Number: WPAFB 08-4512
    6. 6. Powder Coating Overview <ul><li>Advantages of powder coating: </li></ul><ul><ul><li>Elimination of volatile organics (VOC) </li></ul></ul><ul><ul><li>Elimination of hazardous air pollutants (HAP) </li></ul></ul><ul><ul><li>Reduction/elimination of hazardous waste </li></ul></ul><ul><ul><li>Process efficiencies </li></ul></ul><ul><ul><li>Transfer efficiencies as high as 95% (w/reclaim) </li></ul></ul>Distribution A. Approved for public release; distribution unlimited. AFMC 88 ABW/PA Case Number: 08-3215
    7. 7. <ul><li>A UV-cure powder coating is generally an acrylated polymer </li></ul><ul><li>Melts at low temperatures </li></ul><ul><li>The powder is cured in seconds using UV light </li></ul>UV-Curable Powder Coatings Overview Distribution A. Approved for public release; distribution unlimited. AFMC 88 ABW/PA Case Number: 08-3215
    8. 8. <ul><li>Decrease in thermal exposure. </li></ul><ul><li>Large bulky parts that cannot fit into existing ovens can be coated. </li></ul><ul><li>UV-cure powder is faster to apply and cure resulting in shorter turnaround times. </li></ul>UV-Curable Powder Coatings Overview Distribution A. Approved for public release; distribution unlimited. AFMC 88 ABW/PA Case Number: 08-3215
    9. 9. <ul><li>UV-cure powder requires less energy because the energy is focused to a specific part only as long as needed. </li></ul><ul><li>UV-cure powder like all powder has high transfer efficiencies (>90%) </li></ul>UV-Curable Powder Coatings Overview Distribution A. Approved for public release; distribution unlimited. AFMC 88 ABW/PA Case Number: 08-3215
    10. 10. <ul><li>Why Use Robots? </li></ul>Robotics as an Aid to Curing Distribution A. Approved for public release; distribution unlimited. AFMC 88 ABW/PA Case Number: 08-3215
    11. 11. Robotics as an Aid to Curing Daimler-Chrysler Ulm, Germany Cleveland, Ohio Test Lab Development and use of robots for curing of UV coatings has been going on for a number of years Distribution A. Approved for public release; distribution unlimited. AFMC 88 ABW/PA Case Number: 08-3215
    12. 12. Light tunnel approach using various size UV lamps to optimize cost and exposure Robotics as an Aid to Curing Distribution A. Approved for public release; distribution unlimited. AFMC 88 ABW/PA Case Number: 08-3215
    13. 13. <ul><li>High Capital Cost </li></ul><ul><ul><ul><ul><li>Lamps, cooling, fixtures, integration </li></ul></ul></ul></ul><ul><li>High Operating Cost </li></ul><ul><ul><ul><ul><li>Replacement parts </li></ul></ul></ul></ul><ul><ul><ul><ul><li>Energy </li></ul></ul></ul></ul><ul><ul><ul><ul><li>Downtime </li></ul></ul></ul></ul><ul><li>Technical Adequacy </li></ul><ul><ul><ul><ul><li>Complete cure </li></ul></ul></ul></ul><ul><ul><ul><ul><li>Proper Re-alignment </li></ul></ul></ul></ul><ul><ul><ul><ul><li>Mixed product </li></ul></ul></ul></ul>Drawbacks of fixed lamp approach Robotics as an Aid to Curing Distribution A. Approved for public release; distribution unlimited. AFMC 88 ABW/PA Case Number: 08-3215
    14. 14. Robotics as an Aid to Curing <ul><li>Robots ensure repeatability </li></ul><ul><li>Robots with UV sources can maintain extremely close target distances </li></ul><ul><li>Robots can be re-programmed in seconds </li></ul><ul><li>Robots eliminate need for many lights </li></ul><ul><li>Robotic curing is well suited to large or complex parts </li></ul>Distribution A. Approved for public release; distribution unlimited. AFMC 88 ABW/PA Case Number: WPAFB 08-4512
    15. 15. Tools have been designed to facilitate offline simulation of robotic UV curing. These tools allow for rapid path development and solve problems associated with overlap, striping, etc. Robotics as an Aid to Curing Distribution A. Approved for public release; distribution unlimited. AFMC 88 ABW/PA Case Number: 08-3215
    16. 16. ESTCP Project WP-0801 <ul><li>The Problem: </li></ul><ul><ul><li>DoD spends millions of dollars annually on solvent-based coatings </li></ul></ul><ul><ul><ul><li>Hexavalent chrome primer use still widespread </li></ul></ul></ul><ul><ul><ul><li>Contains or requires volatile solvent use </li></ul></ul></ul><ul><ul><ul><li>Significant hazardous waste costs </li></ul></ul></ul><ul><ul><ul><li>Hazardous materials pose risks to human health and environment </li></ul></ul></ul><ul><ul><ul><li>Process times measured in hours to days </li></ul></ul></ul><ul><ul><ul><li>Transfer rates are less than 60% </li></ul></ul></ul><ul><ul><ul><li>Unused paint is costly and adds to waste burden </li></ul></ul></ul>Distribution A. Approved for public release; distribution unlimited. AFMC 88 ABW/PA Case Number: 08-3215
    17. 17. <ul><li>Objectives: </li></ul><ul><ul><li>Demonstrate a VOC/HAP-free, Ultraviolet cure powder coating on DoD hardware </li></ul></ul><ul><ul><li>Demonstrate robotics for curing </li></ul></ul>ESTCP Project WP-0801 Distribution A. Approved for public release; distribution unlimited. AFMC 88 ABW/PA Case Number: 08-3215
    18. 18. <ul><li>Requirements of a UV-cure powder for military use: </li></ul><ul><ul><li>Must perform at least as good as MIL-PRF-23377 primer </li></ul></ul><ul><ul><li>Must also perform as well as MIL-PRF-85285 topcoat. </li></ul></ul><ul><ul><li>Can be prepared in gloss, semi-gloss, and flat finishes </li></ul></ul>ESTCP Project WP-0801 Distribution A. Approved for public release; distribution unlimited. AFMC 88 ABW/PA Case Number: 08-3215
    19. 19. <ul><li>Typical Applications for UV-Cure Powder: </li></ul>ESTCP Project WP-0801 Aircraft components Distribution A. Approved for public release; distribution unlimited. AFMC 88 ABW/PA Case Number: 08-3215
    20. 20. ESTCP Project WP-0801 Aircraft Distribution A. Approved for public release; distribution unlimited. AFMC 88 ABW/PA Case Number: WPAFB 08-4512
    21. 21. ESTCP Project WP-0801 Aerospace Ground Support Equipment Distribution A. Approved for public release; distribution unlimited. AFMC 88 ABW/PA Case Number: 08-3215
    22. 22. <ul><li>Powders: </li></ul><ul><ul><li>Currently considering two powders </li></ul></ul><ul><ul><li>Both in gloss white, semi-gloss gray </li></ul></ul><ul><ul><li>Will undergo strict validation testing </li></ul></ul><ul><li>Robotics/application: </li></ul><ul><ul><li>Will apply powder manually with corona gun </li></ul></ul><ul><ul><li>The robot will carry both IR and UV lamps </li></ul></ul><ul><ul><li>Evaluating two different UV light sources </li></ul></ul><ul><ul><li>Evaluating alternative application methods </li></ul></ul>ESTCP Project WP-0801 Distribution A. Approved for public release; distribution unlimited. AFMC 88 ABW/PA Case Number: 08-3215
    23. 23. <ul><li>Possible future follow on efforts include marine applications. </li></ul>ESTCP Project WP-0801
    24. 24. <ul><li>Milestones </li></ul><ul><ul><li>Joint Test Protocol submitted Sept 2008 </li></ul></ul><ul><ul><li>Robot acquired and integration underway </li></ul></ul><ul><ul><li>Component identification completed </li></ul></ul><ul><ul><li>Ongoing UV source evaluations </li></ul></ul><ul><ul><li>Powder and substrates order Oct 2008 </li></ul></ul><ul><ul><li>Validation testing starts Dec 2008 </li></ul></ul><ul><ul><li>Draft Demonstration Plan June 2009 </li></ul></ul><ul><ul><li>Field Service/Demonstration begins Mar 2010 </li></ul></ul><ul><ul><li>Joint Test Report draft Sept 2010 </li></ul></ul><ul><ul><li>Final Report Mar 2012 </li></ul></ul>ESTCP Project WP-0801 Distribution A. Approved for public release; distribution unlimited. AFMC 88 ABW/PA Case Number: WPAFB 08-4512
    25. 25. ESTCP Project WP-0801 Thank you! Points of contact for UV-curable Powder Coatings ESTCP Project WP-0801: Mr. Corey Q. Bliss Principal Investigator Air Force Research Laboratory/RXSSO Wright-Patterson AFB, OH 45433 [email_address] (937) 255-0943 Mr. Christopher W. Geib Co-Principal Investigator Science Applications International Corp. 4031 Colonel Glenn Highway Beavercreek, OH 45431 [email_address] (937) 431-4332 Distribution A. Approved for public release; distribution unlimited. AFMC 88 ABW/PA Case Number: 08-3215

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