1. haphmeatattom ofLow VOC Surface Coathtgg
'Ibe hciTity wide coavmskm to hw VOC (Vohmle
Organic Compound) asmspece primem and sspcoam for SS%
ofthe coatings usage st tbc ~Dhdsha was
compleuxl oa July l.1993. Tbe tmvhoamtmtal bsos6t wss a
nuuar ooc, reducing pkmt wide VOC cmissions for surhce
cosung pcations by S0%.
Beginning in Augmu 1991,thh pmgnun was established in
response to dm Fu. Smm DER (spsrummt ofEuvimnounud
Rssmuces) requhsmeus to reduce smog fmming VOC
emissionr fmm the six minor paint feei&ca on site. Tbe
implrmtnuuion phm, devehped by SHEA (Safety Health sad
Eevimnmeotsl ABshs), Opmadoas Tcchodogy, and
Materials snd Pmcess Engineer, wss divided into throe
phase%
Phase I involved the ~implcmenmdon of low VOC
w lsrbssed epoxy primem snd high solids topcotus for use on
miTmuy snd commcrdd hmdware dmt cootiibomd so sa
estimated usage of 14,000 gagons/year. This npresented
70% ofdte lolsl usage fsciTity wide. Extenive quaUBcmhas
testing bad bess conducted by the ~Diviskm ssd
Boeing ~T~m Rcaum, Wm, to appmve
dtese new castings befme pmducdoa use. As a melt, Bve
compliant costing ftumuhdoas were sppmvsd for lbs Phase I
implementation which began in January, 1992. Though
these efforts Bbcghy wide VOC missioas worn reduced by
35%.
Phase II mqoind the mplaccmcnt ofsg lacquer mpcoats used
for cxteihr applicatioas oa miliuuy sBcoptem with a high
solids chemical agent rsmtsnt (CARC) poiytusthme coethg
det passed HeBcopters Divisioa qosliiicauoas lasting. Thc
imphmsntstion ofthese coatings, however, foaowed Phase I
due to factory impact. Sigaigcant fsciTitics modifications
were requhed to implement these coatings imo pmducdon to
canus wmhur safety duriag ~Aho their
'ncorponmoo into tbe factory bad to be cmefidly managed by
pmductioa planning snd conuol bccsosc they changed
aircraft con6gmadoa (ie. farm, Br, or fuactkm).
Consequently, ag ~deudls snd assemblies painted
with dus new costing hsd to be identiTied for instsBstioo oa
specific hclicopuxx. This rcqshed mach discussioa with
cusumas m aocept the chmgn aad poht of~as
wcB ss ~msapower to ~tleir
implemeamdoa snd coatnd ahaaa ~.Pham B
impscud IS%of tbe uual (20JXO gsgoas/year) coadags
usage, android VOC ~by an sditkmal 15%.
Tbh effon wss cmnpletcd ou July I, 1993.
Pbsm III is ongoing snd involves tbe qasiBcstion and
implcmmmu'oa of~for the nmuuniag coadngs,
mahly special performance coatings aad adhesive prhners.
These mslsrish compmmiss tbe ramsinhg 15%of the
smhce coathgs usage at HelicopuxL Tbdr hw VOC
subsdtutm wgl be tbe mots difBcult to qualify dae to thc hck
ofcurnmdy avaBable alternadvca Tbe Boriag Company,
however, bas baca ooducthg an htsosive effon m find
suhable mphcemmus. An dsbonuc inungvisiond
aebaQqp exchange netwmk bas baca eneblished to
~infonnatioa and mpmt pmgram statuL Desphs
the scheme dilBculty in Bmgag adcquam mphcsmcnts for
nuns ofthese coat'mgs, ~Diviskm mndns
spurn'stic oncmning the ssccess ofdds effort snd is actively
ssehng sltmnstivsL
1bc~Division ofthe Boeiag Dsfeosc snd Space
Omup msaufscuass Tsadcm Rotor Hegcopuxs for both
mihuay aad ~applhstkms, and nut)or wing
ssschiss for BCAO (Boeiag Commcmisl Ahphme Gnmp)
lu Seauh, Wss
'
igliui. Ia adtgdoa, this Division is nlgsged
ia two mtttor dsvelopmcat progrsms fm the miTimry to
msauhcuue the RAH M mconnaissance snack elicopux'
sad dte V-22 Tilt Rotor Ahcndl 1bsse air vehides snd tbc
aforememicosd pmductiaa cicopuss ead commemht
hudwam perfmm special and mdmr unique fimcdoas in
mrvicc wbge being exposed m a variisy ofesvimsmenud or
ouumh
'
BucaccL 1be various peiot systems m "Surface
Coatings" med lo pnutet these prehcts Bom harsh
cavmmments must meet spedBc perfonnance equkemeats
m hub company aul custsmsr sptcigcstioos. Fsilme m mast
dtese cduria jopsrdixm busmess base, positioa with
customers aad h some cams tbe lives ofcmw members snd
passengers For this reason, particularly the lnu one, any
Preteetes et tbe Attterbcte Hexceyter Seciety I let Atettttr Pereec
Pert Wertl. rx.Hey S-II.IN5. Ceyyrtrbt 0INS by tbe
eteericee Hdiicepter Stciety. Iec.AR rlrbte reeerted. ltw tec
1697

2. mqior change to tbe design ofahciafi aad associated
barrhvsre, namely paint, mvrdves extensive tesung snd
Mowed by a myriad ofmvisioos to ~drawings, msteriri aod process specificstioas. snd
msnufitcturing plans prior to pmductkm imphzsumtatknz
Once the new coatiags am im~ manufactaring must,
in many cases. Boduoagh an exunmely arduous lesraing
pmcess m opdmize dm apphcstion ofthese uuerials while
isrict cus oulcf IopUNDlMB.
Qsan Air Act egnhu'ons fiom the PederaL Shun, and Local
level limit bszsrdoos air missions fmm smfsce cosungs
opemtions. Ccnain solvents ~in these paints
evaporate into tbc ~during application, and
pbotocbemically react in tbe preseace ofsuolight causing
smog. One ofthe major componems of smog, ozoac, is
hazardous to both humans and plant Bfe. Tbc EPA, thmugh
the Clean Air Act, reydsm geese szsrdoas emissions by
establishing barn&no connois to lhnit dte smmmt of smog
formers present in the aunosphere. 'Ibe State mgtdators may
hl!Nunc cases, hnposc cvmi oleic stringcat reqililcnelts dzm
the EPA, if they are iu an ann ofozone non-stis' meat.
Such mquhements drive many diffenmt industries, including
semspsre, to implement coauols an their uufacc cosdngs
endssioaa In tznue cases, dds means subsdwiaa widt a
lower VOC material that meets aregulatory threshold. Or in
others, it would reqtme the instsation ofstack contmls ia
dm paint boodts to Blmi ~air fiom uristing high
VOC coatings. Tbe lauer option, however, is merely a short
tenn solution with high non-rccaning and recmring cossz
The ccospsre indmmy, as with other industriru mgulsted for
surface coatiag pmcesses, mrna make imporumt businem
decisions to reduce eavironmeund risk while minimizing cost
ofchange. Available options to reduce dds ridr (ie. end of
stack contml technology va material subsdtution) wme
evaluated by Hclicoptem Division management prim to
pmdacdoa implemeauuion. A clear undenasnding ofdm
costs of dmse opdons coaphri whh a loag inay, vision oftbe
reydatory cfimste wss needed m make tbe righ choice. The
remit was to ~low YOC alternatives and minimize
pogauon at the somce.
Tbc challenge to execnm a fnciTity wide conerskm ofhigh
VOC coatings to rdteinsdve Iow VOC ~in a short
time frame wss aa exuemcly diificult sad cxpcsive one.
The obvious rnvimnmmusl beae6ts mu wonh noting again,
however, ofeqosl m greater impmumce is thc sbiTity ofa
large company to sdtqu m ~changes while smying
focused on their primary objectives.
Facgity wide ase ofoomplisnt low VOC smfitce coatings
(c3Slbfgal as ecreincrB.
QldCCkhg;
Rcphrccmcnt of ag non~pgaat surface cwuingz with
compliant coadags ht one year.
7bc plan to hlly coavcri tbe e&coptem Facility to drese new
coathlgs incllldcd Ihc fofiowing hcy clcmcatu
I. Industry Survey
II. Qualifications Testing
IIL Specificsdon Coverage
IV. Imp~ Study
V. Poducthm Imp~
L Indludry Survey
Mstciias Enghtcering aod Operations Technology
investismri the avaihbiTity oflow VOC candhhun primers
sad topcmus that would satisfy aB Heiicoptcs Diviskm
perfounaacc requkemeats for miTiuuy and commercial
hebrew Qualificd PioductsLhas for pp&Bcrdde
specificadoas wsza mvbwcd m identify de avsBsbghy of low
VOC coatings. VOC compgnnt condo&a bsd ahesdy bees
deeloped for and spproveri to many ofthese specifications.
As a uuult, the ~nuuerials wme selected fm
quaBBcadtms testing.
~ MIL P455&2 Type I, Qsss I Epoxy Primer
Vendor. Deft
- to mplscc: Tl'-P-1757 Zinc Quomste
MIL-P-23377 Cl I Epoxy Primer
~ MIL-P-&55&2 Type I, Qass 2 Epoxy Primer
Veador. Courthsulds
- to replsctz TT-P-1757 Zioc Cbimnste
MIL-P-23377 Cl I Epoxy Primer
1698

3. ~ MIL-P-23377 Ches 2 Epoxy Primer
Vcadar. Evmmnl
-to rcyhcL' Tf-P-1757 Zinc Chramsm
ML-P-23377 CI I Epoxy Primer
~ MLC-22750B Epoxy Taycaat
Vendor. Evennal
- to raphael MLC-22750 Epoxy Tapcost
Narc: Revisioa Eto spec. far high sagds epoxy
~ ML&46168 High Solids polyunsbsne Tapcaat
(Chemical Agent Rerisuet)
Vendor. Defl
- ereyhcm Tl'-I 20 Lacquer Taycoat
TT/12/CSS97 Lscqms Taycaat
MH L46159Lacquer Topcoat
ML-L-19538 Lacquer Tapcoat
~ MLC-85285 High Solids Pnlymethme Tapcaat
Vendor. Deft
Caurthsdds
- to replace: ML&413286 Poiymmhsne Tapcast
Boeing Msterish Tccbnolagy (BMI)wss caductmg deir
own evaluation at thh time to appove law VOC prhnms and
mpcosn for ose aa commerrisl shmnfL Sehcssd camhhmn
wme being tested Io reyhce the foflowiag high VOC
nnerisls used on commmcisl bmdwsre msnufactmed at
egcoptnz Divisioa. lhne wme:
~ BMS 10-11Type I,Grade A Epoxy Primer
~ BMS 10-11Type 2, Gmde A EPoxy ToPcoat
~ BMS 1060Type 2, Grade A Pnlymetbsae Tapcaat
~ BMS 10-86Type I,Grade A Teflaa Fifled Coating
~ BMS 1046Type 2, Grade A Teflaa Iqfled Cmuhg
Adbesha of Ihe prhnms m chmmme ~caved
ahmham is a Mopes requhcmeaL Howevm, thee
speriflcmioas dbl nat abbess primer adbesiaa m ader
substrstmmto a ctevetshe coming which bad "aged".
Recogaizhg that dehys nese yossibh ia a poducthe
eavhoamcnL a 1-2month delay was iocmpmucd whee
applying de campflsat prime m almuinum panel@ Pnht
sdbeshn to mhnr suhmmmrepeseating actual He 'coptem
parts wme caacaneNy hvesdoued.
Primer/ Vendor. ML-P-85582/Courthaulds
MH P415582/Deft
MIL-P-23377 Ci 2/Evenesl
Sbzttsten
4130Steel - cadmium plated per BAC 5701 Cl I,TII with
oae coat ofwash primer, per MIL-P-8514
AZ31 Magnesimn - coated widt One Of the following.
L Conversian coated per BAC 5609
b. Light HAE Amxgsc
c.Heavy HAE Anodize, per ML-M45202
Primer Appflcsthnc
Two cmns ofeach high VOC poducdoa prhner and hw
VOC csadidam primer wme apphed ta each subcaste
(0.001 - 0.002 hch nasl dry thicknem).
Test Proccdmm
1. Wct Tape Test (FED-STD-141 Method 63012)
2. Scrape ~Test (ASTM D2197-86)
IL Quallflcatlons Testing
lie six crhicsl papenies fm ecch low VOC csadhhue anted
st Hcicapem Divishe were:
L Primer-to-Suheste Adhesion
H. Tapcost -to-Primcr Adhesion
IH Crack etectian
IV.Huid Resist
V. Reacrivsrioa
VL Crevice ~
Resehn
Wet tape adbesiaa for tbe three campliant primms ayplied to
sfl lbmri suhannm wem ~whh oae cxacydae-
Mt's 44GN-7 per MH P-SSS&2over canvmrion cmmri
magnesium. Scrape values far tbe dues compgmu pmners
wme ~since they wme campunbh tu cantnd values.
both ia average snd warst case data.
Candusiona/Ream mendstimzc
~'sprimer, which cmeuncd smetimn cbmnnue,
yielded ~test resohs, wbmeas tbe Deft primer
cmeiniag barium chmnsm did aot. Prmxnamcat ofs Deft
planer cantahhg stranthm hlonlste was advised ta
cvalmne a second quslifled sumac ofMi F45582.
1699

4. it was ~dua mail foll imptemenmdon ofknv VOC
pnmcm and topconts, them coald be an husrim pmiod dming
which a mix ofkrw aad high VOC coatings woaM be sppged
to ahcraB (eg. applying cmapbant topcoats over noa-
comptbtm prhned surhtoes). Saduibctory adbeshm in this
case woobl pennh depbuhm «fedsthqt stock ofhigh VOC
paints. For dds reason, combinauoas ofexisting noa-
complisat coadngs whh compgam coatmgs were evatoaauL
Chmnuue conversion cosmd almniaum test panels were
painted with two coats (0.00141.002 mcb total dry thickness)
ofemh primer hated below:
I. TT-P1757 sine cluomste primer (cannot)
2. MII P-23377 Class I epoxy primei (control)
3. Mll P-23377 Ctsm 2low VOC epoxy prhnrr
4. MIL-P-85582 low VOC Deft" epoxy primer
5. MII F45582 low VOC "Courtbaulds" epoxy prim
Within four burns after primer application, the test panels
were ~Oae coat (0.001 inch dry thkknem) ofeach
topcoat listed below, was applied to emh sct ofprimed psaeta
1. TI'-L-20 high VOC lacquer toPcoat
2. MIL-L-19537 high VOC bxxgstr mPcom
3. MIL-L.19538high VOC lacquer toPcoat
4. Mii L46159high VOC lacquer topcoat
5. MIL-C-22750D high VOC ePoxy toPcost
6. MILC-227508 hw VOC egoxy toPcoat
7. MIL-C46168 hiw VOC palymetbsne topcoat
S. MILC45285 knv VOC polyietbsae topcoat
9. MII D-2%03 low VOC walkway coating
After opcoadng, the trm panels were cmed at mom
tempenmne for a miaimmn ofsaves dayx
Test Pmcedme:
1. Wet Tape Test (FEDSTD-141 Method 6301)
Results:
Adhesion ofall tweed topcoats to primers was ceptsbte with
onc excepthm —Mii I 19537lacquer over CouNumM's
MIL-P-85582 primer. CompsdMity ofall other compliant
primers snd topcoats ai conuol coatings was verifuxL
Conctusi~mendadonn
MIL-I 19537lacquer, tbc oaly eceptioa. was not a concern
since it was not fmmotatsd fcr applicsdoa to an epoxy prbner
(it is specie for MB P-7962, a high VOC lacquer primer).
Punbennme, MIL-I 19537was scheduled m be phased out of
ploducdon
Overhaul of"fttgbt cridcal" toter and drive system
omapmieats tequhe
'
specticn fcr cmobs which may have
dtelopai in service. NmHbuantcdve spectioa cbtndques
me effusive Sar crack dmccdoa where tbe paiat is smpped to
bam mimi snd for cenatu britde paints, wbme strippbtg is
not iequhtxL Ptdnt stripping is dme caasamhe, dighxdL
snd an eavinmmenml baxmd shies cbeudctd stripplng is
mquhed in dds case. Tbeiefme, using a pahu system duu
will crack as tbe metal mbsmue cracks was highly deshable
for this quatigcadou. Various combinadons oftbe Mown
paints were udgxak
1. MIL-P-23377 Class I epoxy primer (conuot)
2. MIL-P-23377 Clam 2 low VOC epoxy prima
3. MIL-P 85582 knr VOC "Deft epoxy pruner
4. Mii p-a5582 Iow VOC 'Counhaalds" epoxy primer
5. MIL4 -8514 bjgb VOC wssli Primer
6. MIL~750D high VOC ePoxy toPcoat
7. MIL4:-22750E low VOC epoxy topcom
8. MIA."MI68low VOC polymethane topcoat
9. MILZ45285 Iow VOC polyuredume topcoat
Substistes:
7075-T6 aluminum - chomsm conversion coated per MS
6.16
4340 Steel - cadmium plated per BAC 5701 Class I Type II
ZE41-TS magnesium - light HAE anodmri per
MIL-M 45202
Test Spccimenn
Twenty trm specimens were macbbud fmm emb oftbe three
btm (2.0 x 4.0)inch "dogboaes" and prepared for
pshuing. A (1.0x 4.0) inch wide strip ofpaint or
combinatioa ofpaints that represent pmlocdoa pans wrse
appUcd an tbe ceamr leagth ofoae side of dm dogbane. After
aman teuqieimme sevco day mioimum cme, each specimen
was noscbed at tbe edge oftbe tnn sectioa, oa oae side
duougb tbe thickness near tbe ccnaugne of tbe length. By
applying an ~fatigue loaL a crack was hutuocd
iato tbe costcd mea of each ~Test Procedme:
1. Flaoesceat Peneeant nspectioa per BAC 5423
2. Dye Penchant Inspection per BAC 5423
1700

5. Grouping s& 59crack est spacimcas cofiacdvdy (ae wss
"consumed" fm sct ap in &cuing Fsdgae Machine), a mh of
singh sad m lticosts ofVOC compbsat anima~&sat
primers snd epooats warn ~Cmck pmpagadon
tbmogb de paim(s) wss such that de NDI~ crack
knyh wss yester dea de subsuass crack laoyh for most
spacimem There wme nore hrgc dfiamscas wbkh
rapnsaat hihoe m pm&agee a atua&arable crack in det
perticubn paint sysem. 1lecrack laayh pnxhced even
duoogh four cone oftwo VOICE - complima topcoats, MIL-
C-22750D Epoxy nod MBA:46168polyntaduue (ABC)
WhM. ~l $$ t Mt
for MIA'. 4S285 VOICE -compliant polyumdene and flu
MLC-22750D norH»mpgotu epoxy topcoat over Defeat's
ML-P-&55&2 compliaat prime. MBA':22750D topcoat wss
~for crack etactire whaa applied to sfl ader
prhenx
Non-dastmcdve uat crack dctacdoa tbmugh sfl primers sad
topcoats wss acceptable whh two ccept'ons —(I)MBA:-
85285 Polymedeac topcoru and (2) tbe combinsthe of Deit's
ML-P-&S582 Epoxy primer snd MIA:-22750D Epoxy
epcost. App 'catioa of these paints should be restriced to
pans in which crack datacdon through the paint is not s
considarsnon.
MILqec fluid reiststx» nquiremcots. for thc dnec kw
VOC primcrs, did not indude sfl nuuarhh which wodd
contact painted ~Division psnL A compeoMhy
investigation of elicoptm spacific msterisis in conuet with
dfifcrent paiats wss aadertskm m pmvide de misshg data,
Two cess (0.001O.002 hch total dry dudoem) ofeach of
the following primers ware applied to chmnuua conversioa
coster test psoebc
1. TT-F1757 sine cbmmstc primer (contml)
2. MI P-23377 Qass I epoxy priaer (sound)
3. Mi P-23377 Qsss2kw VOC aPoxy Primer
4. Mi F45582 kw VOC "Defi"epoxy primer
5. MB F45582 hw VOC "Cotudumbk" epoxy priaer
AB panels cmed at nem tampcnmne for saran days (mh ).
Test Pmcadee:
Each set offive painted almninum panels wcm immersed or
costar with the foflowing msuxisls for seven days, alter
which thc dfccts on de painted subsuatcs were evahuuad.
1. MIL-L-7808 h ricstiag oil
2. P-D 680 sdveat
3. Jet A hal with Prba (and-icmg sdr&dve)
4. ML-H-S606 bythmlic oil
5. 1,1,1 - Tdcblaocthue
6. Trichkmcthykte
7. MLO41322 yeas
8. ML-T43483 snriudsa eompouad
9. Syo-Tach gnese
Immened panda wee nsnovcd fiom tbc Ibdds sflar saves
days snd bkmxl whh a dean ~.P-D- 680solvent,
whkb did oct deyndemry primer, was used mremme de
applied yese fmm tba out peach. AB paaals wme vbmn&y
cxsmhad snd pmbad with a wooden negus depreaux for any
oridaoce ofprinxx dayadstiaa ME P-23377 Class I sad
Ddl's MIL-P45S&2 primcm passed saves days aqesme to
thc nine conuet uucsisls. lie other primers fldlad oaly
l,l,l - trichhmedume snd trkbhutetbyhm huacrskrx Two
kw VOC primers (CounhmM's MIL-P455&2 aad Eversasl's
Mi P-23377 Class 2) hilure modes vsricd fiem s&gbt
bflserhg or paebag to mvembflstariag.
Cond
Defi's MIL-P-&S582
primer
gama»uste acccptsbk
to afl de msssrish tastnL A scves dsy immersion
in TCA or KX,which ML-P-23377 Clam 2 snd
Ooutbsah's ML-p4SS&2 primcn did not pass, msy be
vs. band wiping with dese solventL A reduced
dmc eqesme uut may have baca uxxe mesahtgfuL 'Ilesa
too primcrs wme ~acceptable whh a~note ~TCA sad 1CEcleamng and cxposme (eg.
vapor eyesiog). Both ofthese advene however warn
beiag phased oat at this dme for cnvinemaaod coaccmL
In pnxloctioa, ifs significant daley occurs between primer
snd topcoat spp&cstkn .the "aged" primer must be
rascdvsaxl to easme adhesion ofde topcoat. Ceruun
Helicaym finish codes slow an optional chemical
teacdvathm oftbe primer in lieu ofde ML-F-18624
nxpdred plocedNL This lascovstea pmccdum wss
evaluated for the tnv VOC prhnar qaaflficsdon. If
uasadshcuuy, sa shmmoe paoccdme would be nacesssy.
Two casts (0.001O.002 inch maI dry bickness) ofea:b
primer listed below, warn spphed to chromos coaverste
costar shmdnmn est panebx
L MIL-P-23377 Class I epoxy primer (contml)
2. ML-P-23377 Chas 2 kw VOC epoxy primer
3. MIL-F45582 low VOC "Deft"epoxy primer
4. MIL.P-&S582 kw VOC "Coartbsuhk" epoxy primer
1701

6. l. One dey at mom empwwme
2. Two days at mom temperstme
3. Seven days at mom empenmuc
4. Accdcrated cwe: 20-30 minuua at man ampereaae
foBowcd by 6000mhnma nt 12SF
Test Spccimca Pnqtwminw
AS cwed punch wwe vriycd with aceuxe to remove aay
swhce amtnmhenta S~y.tbe panel swfeccs wwe
wcacd with ML-T-19S88 solvent aud eSowed to dry. A thin
coat ofthe hhaticsl primer wss nppSed to each tcn psael
withia four bours ofmscdvation. All mcoetsd panels wwe
cured at mom temyerstwe for seven days minhnum.
Test Pmcedwe:
1. Wet tape test(FED4TD-141 Method 63012).
Resultn
All en panda passed nectivsdon tcsung. Thee was no
evidence ofsny primer adherin to de ahuprly pulled tape or
say lihing ofprimer aSer wct mpe test.
Condusiona/Recommendsdorw
The three compliant prhners evelmued can be ren:tinued,
when rcquked, by the cunendy used ~
Smove dhecuoa wright enghs to oee aaother fsdng de
spedmen. This wss beld mgetber by aboh, two wssbers and
s nat. A polyethyhne shave over de bolt enswed electrhsl
isohtica ofeach aet specimrn.
Ten Pmccdnnx
I. AS134G48-76 -"Ten Method fcr Piniag aad Ccnoskm
Rcshuwce of Stnhlem Seel and Rchusd Alhys by the am of
Feme Chloride Solatkm"
Resuhc
Each primer d'scoiced but sdg meuned its integrity such that
conoion of de 4130steel subsmus did not occw. Howcvw,
Cwutbauld's ML-P4SS82 primer showed nwnwous small
bhwss over the enthe syedmen smfsce. ML-P-23377 Qsss
2 bsd s few snail bgstem located mu ofde spedmen aet
mea. No vinlde cwrosion wss musd when a nmnber of
bhuws wrac au away to oberve de snhstnue smhce. Feme
chhrhh soladca wns oot present in the "boBow" hihuw.
Cond
All thee hw VOC yrimers ymvided aevke ccnoske
fcr tbe 4130easel en spec'mens. However. based
upon de test results. de prefened ~ofhw VOC
primers ro yevent aevice conoshn is (I)DdYs MIL-F-
85582, (2) MIL-P-23377 Class 2 end (3)C urthsuld's MIL-
P-SSS82.
In 1990,concerns abmu pwamal aevice cwmsion pmblems
of4XXX~shel wee rwelved Som a 30day ~tnu mcded evalasring sevwul cwuhgs. It wns demweumed
that MIL-P-23377 Class I high VOC primer pnwided
ccceptnbh aevice conoskm pnectioa Evelwuha oftbe
three VOC -compgaat prhnws for aevice conoshn wwe
also ~.
l. Mii p-23377 Class I epoxy primer (conuol)
2. MII P-23377 Ches 2hw VOC epoxy primer
3. MIL-P45582 hw VOC "Dcit"epoxy primer
4. MIL P45S82 hw VOC Cowtbsohh" epoxy prhner
Test 8pccimenn
4130Steel -Four (025 x 2A) x 2' inch whh sccotenri
5/16-inch diameter hole. wae csdmiwn Flail per BAC 5701
Class I Type II, snd yahwri with one coat ofwash yrimcr per
MILC4514. Subsequently. each specimen wns coated with
one oftbe prhnas Ihmri above. Each tnu specimen wes
betwcea two Tefkm phtm (025 x 2.0x 2.0) inch
each with (0.040 x 0040) iach Smove full length oa the (2.0
x 2.0) inch face. lie two phew wae yosidoned with de
All qasliScwioas test dam hd m be cweSNy mvicwed by
Material aad Pmcess Eagineeriag begun specigcstkms codd
be revised m ~the new uuerisla lie ympcrdes of
greaten cweern wae (I)edhcsioa ofde primers evarious
~(2)adhesion oftopcosts m primrrs snd (3)
acceptable crack detection thmugh de various paint systems
using non4cseucdve inspecdon pmcedwex Based upon this
aheris snd de tnu qua scaunulated, tbc following
conchuicns wae msdn
1. Tbe Dch ML-P4S582, 7)qe I,Ches I,No. 4443N-7,
her VOC primer wss unmctgushh based uyoa pour primer
sdbeioa to Dow 7 coated megaesimn nnd uassthfectory
cack denedoa daough dds primer in combinstioa whh two
paint topcostx
2. Connsuld's ML-F45582 Type I, Class 2, No. S13X408,
low VOC primer was acceptsbh for use. This judgment
couskhrrd blhuering of the yrimer, which sdII ymvided
aevice camskm pmtectkm, snd incompatibility ofthe
primer with TCE sad TCA solvents ss acceptable
perfonnance Ihnitadonx
1702

7. 3. Siace an sharmue comes ofML-P4SS82 wsa dss'rable.
soma ddB 'dorud msdng was memtmeadeL Choices should
include Dah's ML-P4S582 Type I,Class 2, whh suoatium
chomstc to nuucb tbs varsho from Counbsuhh.
4. ML-P-23377 Cbuu 2 (a high solids vesioa ofQsss I)
hw VOC primer wss ~for use. This costhg system
however, was nxymed for wet ieedlaim ofhneaes in Bsu
oftba Mll P4S582 ~primer wMch was stthtcd
fmm thh opestioa to mhdmise cormsioa palatial in water
trspyad mess. Shop BBcatcsin spplymg tbe ML P-23377
Qsss 2 yrimar jasd6ed adidoaal invemgadoa ames dm
costmg pefmmaace was ccccytebh. Also, irs usc woold not
have mquired aay Baish code m dmwiag revishrus ushas tbe
Class wss pccifieL
S. MLC-227505 hw VOC Epoxy tcycost wss ~for me based apoa pessiag aByerfonnsace tests
6. MIA:46168 low VOC chemical agent resisamt coating
(CARC) polyuredume topcom was ccaytebh for use. Tbh
wm bmad uprm psssag sBperformance rests. Cosaxner
pmfeenca wss fm thh ceuhg over ML4:45285 because of
its chemical agent esstenca ppertier.
7. MLC45285 hw VOC polyletbsae topcom h
conditionsgy ~for um. Tlris mpcoat wss coosideed
unacceptable for use where crack etectiaa duough tbe paht
was required, but ~whee s toogh, waubcr~L
hw VOC topcmu was nccdeL
8. BMS 10-11Type 1,Grade Ewater nxhcibh epoxy yrbner
wss appmvcd for pmhctioa use at ~oa
commecial hmhvme. This coating passed aB qualiTicsdoas
uming canducud by BMT snd wss incoqxxated into tba
specificsthn oa Much 11,1991.
Oa December 20, 1991the foBowing hw VOC -comyhent
surface coatings wee sccaytM for production use at the
Division:
1. Mii P-23377 Class 2epoxy primer
2. MIL-F45582 Type I,Class 2 epoxy primer (Counbeulds
edy)
3. MLC-227508 epoxy topcoat
4. MLC~ 168chemical agent rcsiasnr polyretbene
topcoat
5. BMS 10-11Type I,Grade Eepoxy primer (Deh mdy)
Limited infmmatica wss gadmmd dming qusliiicadons
mmag ~tbe bebavhx oftham new nuasrhh dming
Msnuhctmhg ~were ccaductrd at
dm tbne lo dahmnhe de best ~to successMy
ayply these sssrisls ia a pmdactha mode. Tba sppBcstioa
afthese cmuings requhed a diffamat sppmach by tba oyararrx
lo eiectively apply theat Im ~parts. Ibe nuttor
issaas ead conccms with respect to pmducdas pyBcetbm
~ Dry to Topcoat Time
~ Pct Ufe
~ MElt Mlxlag
Pmdacdoa fhw reydred a hager dry m mpceu dme for tba
Mi P45582 Type I, Class 2yrhnrx. 'Iba contmglag
pmcem sycci5cadon, BAC 5807, speci6cd a 4 to 24 bom dry
to aaycmu dme whbout mscdvsdorL Msnufscuuing required
a 2 m 36hour window due ao tba hck ofa tbhd shiiL
Eaginaering sst ap an ia boom test to verify if this pmduction
demand couM be met without resctivsthg tbe prhner.
Teuing nuults wee ~sad tbc syaci6csdoa was
revised to rc5ex dra new time Bema.
Purdadady critical with tba BMS 10-11Type I,Grade B
water raduciMc epoxy primer fmm DrdL Tbe pot life ofthis
sysum was Rur borne m men tampenuue compeed to eight
home for tba Grade A high VOC versiorx At 90Fwith high
rehdve bmnidhy (&$0%)tbc pct Bga wss ~ymdaced m about trna boar. This wss an ~lecoodhioa in pmdactoa. Tbc solatioa wss to cbiB bmb the
mixed paint md mmdxcd compoaeats at m above tbe
minimum axnpcnmne of 50P speci6ed in the cantmBhg
pmcms speci6csdoa pcr BAC S632. lbe ~ofa
frigsread stomgc box fcr tbe unmixed crxnyoaaars
(including deioixad water), aad small ndiigerators for drs
Bve gsgoa preasme yots canned a four hour pot hfe dming
tba nunmer months with high bast ead humidity.
BMS 10-11Type I,Grade Eprimer wm scnsldve to the
mixing ymcebna Tbe foBowiag stays were critical to this
ploccac
1. 85x ag (anthe ldt) ofcoaqxmeats A sad B.
Note Kits werc not m be hokea down.
1703

8. 2. Stage nduce wsau in oae-tbhd amounts, mhing
thomugMy after each nducdurx
3. Mainudn viscosity between lg - 22 sec. in aZsbn 2
cup.
On Jsnumy 22, 1992,tbe imphmentsdon ylsa wss nwiewed
by peesdeaws T~with dm sflhctrd imctiond
«gsnhsdoas lbc nut)«sgeada Items were:
~ Review bsckgioond sad pmgrsm status
~ idnldfy under issues
~ Basblish imylemcnueou team
~ Impbmcatstion Plan
2. MIL-P-SSS82 Type I,Ches 2 epoxy yrhner (CounbsuMs)
3. MILC-227StRI epoxy mycom
4. BMS 10-11Type I,Gnde Ecyoxy primer (Deft)
lbe MIL4:40168 bw VOC polyureduum topcom
nyheeamt f«hcquers, an the other band, ctmld not be
implemented by Ab Aua ibis psrtbuhr paint system
changed Ae elicoptcm perfonnance requhemcsts or
conflgmatioa dae min chemical agemresisumt popcrdes,
snd ss s nsuh requhcd hah customer syymvsl sad
elfecdvity cmeol m Ae hctory. Ms menu a ~scbcdub shde gsr pmductiaa impbmcatmba. A sepmme
schedule wss needed f«Aese comhgs that would reflect the
time lines for cbsages to customer caescm snd ymducthm
phasing iequhemmts to c«eol shcrsfl effcctivhy.
Oae teyrescntadve wss sebctcd flom each ofthe folbwing
uncdoosl orgsnisstioas to easMsh an effecdve
impbmeatmhm tease
Total High VOC Surface Coadngs
Suhaiuaas Approved
Coeaiom Without Sohmtuas
113
llsr qualificsdons tesung wss comphsed on December 20,
1991. The imylementsthm date commiucd to was Augast 2,
1992. The foflowing coatiags ~was idcndflnk
Opstions Tecboology
Invmeuy Management
Contracts
Qmdhy
Flight Tea
Mihuuy Pmgrsm Olflce
Oflbad
Ovarhml Pmgnun
Comm«nial Support
Ssbty, Health tk
Envimnmcaud
Msteibb Eagineering
FsciWies
Design Engineering
Manufacturing
Pmject Enghccdng
hdustrial Engineer
Msnufsctming ngineerhg
Spans Program
Paint Shops (Six)
Pmducdon Planning A
No Sabstiueu Rcquhcd
Subsdtutm In Tna
bhtjes Impbmsatatios Imasn
Pmductioa Phmning changes were required for the following
plognmltc
CH4d dt CH47 Helicoytem
Subcontmcttus
Spares Progrmn
Overhaul Pmgnun
Weekly mcedngs wne scbnhded snd caordhutud by
pistions Tecbnobgy. Meedng minutes were pblishcd
ideadfying Ae major issms, action items assigtuxL sad Ae
msm member ~for each sctioa along with Ae
required completion dare. A master schedule compiTing Aem
uncdoasl scdons wss devebped snd conduimlly updated for
tntm mview to provide acoonlinatcd impbmeauuioa.
Many sccomptbbmcre were made by the team members
~Ae course of these meetings whbb continued on s
weekly basis for sixteen months.
lbe folbwhg hnv VOC epoxy primers snd topcosts that
comyrised 70% ofAe fltctThy usage worn to be impbmaucd
by August 2, 1992:
i. MIL p-23377 Chss 2 epoxy prime
Although many unponnu macs wme ddressni durmg Ae
implemeatstion phase, the corn pbdoa oftbc folbwing
mitmtones wne critical to the success ofthis effete
1 704

9. ~ Dlvhhd hlplemt¹mdon eifiut hto Phasm
Pbam I - Epoxy ydmcm and mpcaus
Phase H - Polyurethane toycosts
Phase IH - Fstae implemeamdca
~ BMS 1040Tyye 2, Gmde D Polymetbaae Topcaa
~ BMS 1046Type I,Gmde D Tc6oa Pi6ed Coadag
~ BMS 1046Type 2,Gmde D Tefhm ymed Cauhg
~ ~imylenu¹tadca d¹cs fa Phase LRH
Phase I - Aag¹a2, 1992
Phase H - Augu¹? 1993
1. Quslifhations coa'mg wss coahctM at sander
Boeiag hcghy dadng Pbase H hnylemcnmthoL
~ Released Ossa IEnghmering Change Pmposal NCPJ for
polyatsbane topcaus
- Required for customer sutorhation and
reconcgistion to tbe ccaoact yrhr to
implemeatation
~ Established cutover point for polyaetbncs
Abash 3439 - Delivery ia July, 1993
ogistics ofccaversion based upon exhsing
hvt¹taieiifhwdme m ensae 100%
incapomdoo, BCP lead time, snd time frame
fa customer ynxhcthm nms
~ Inidsud Pnxluct Revisioa Rccad 145-2195
- Coatrolhd ~snd incatxustha of
yolymeUum paiat for existhg connects suudag
with shcm6 3439
~ ~hcaporsdtm ofIeworh phnohg hr
pmvhosly psiaoxl lacqscr hmhnue ccedahd for final
assembly past caovcr pohu
~ Ptda Adhesion
~ Toocb IJy
~ Iqnsl Ahaait Paint
MsteriaL 444HI-I I Water Rahcibh Epoxy Priner
Vendor. DOR
Boehg Spcci6¹mac BMS 10-11Typo I,Gmdc E
~ Esmblisbed a method to provide part number unusability
tbnmgb hcqucr to polyaetbsae convershm witboa an
ginecring part number change
~ FccTitste of facuuy for polyaetluum application
- Appliauion ofpolyunbanes mqtrind ysint
room isolation and bmsthsble Bash air
Pbsm I imp~ wss complesxl by Aug¹u 2, 1992
end insulted in tbe conversion of70% of~Division
sagtce cosdags usage. Gn July I, 1993full amvendca oftbc
odHtary ptdnoedurom wae incairoratcd ha the dtctory
caaphtiag Pbam IL 'Ibis eifat shag with thc
imldnnauatioa oftbe ~casings spyroved by Bbff
for commacial airuait subassemblies amtrihocd to sa
additioaal 15%coavemhm based oa usage:
~ BMS 10-11Type 2, Grade D EPoxY Toys™t
Backgmo¹L
Altboagb all anodhnd alumham surfsao wae affected,
cmicaHy milhd sahces bad a Idgher haysmcy ofhilae.
'Hm msjorhy ofthe paint failaes occarmd daring assembly
cyemt'oas mound rivet beads and ddll hdes bat wise not,
however, limimd to these mess. Siignidcant dowatime and
addidoasl labor costs noulted Bom tbe ssochtcd mwak,
ifthc reworh mquhed removal oftbe hgcd part
fnsn tbe assembly jig.
Sutycct Csos¹
Srohce amt¹uhsdca aod anodize process vsrinbhL
Ibis nes paint sysmm ¹emed to be mae senshbe m
Bnisbhe pmcem ariadoas dma tbe ohl solvcat bmcd
hmnuhnoo aad this sosyhhm was coa6rmed by aber
Boeing Divisims.
1706

10. Temng snd E~A scmp ymt whh adhesion Mun» on chem-miged and a»-
milled suihtcm was seat m Boeing ~Technology Scr
evslustioa Smface aaalyals wss perguaud m hok for
posibh surface coatsminams and m dcmrmiae tbs mode of
failms.
Analyshc
ESCA (Ehctnm Spectmscopy for Chemical Auclysis) smhre
analysis ofboth dm primer and dm suhmase side ofd»
hihue did not reveal aay ~txmumdasnts.
Tmt Resultu
Thee wss a sigaiBcmt smouat ofslmninmn oxide oa tbe
primer shh which indicmed a cohesive Mme widua the
anodize layer.
Conriusioau
The cohndve Mure widun the anodize layer ~pmblems with the anodize pmoess. Sohtion ~temperature, volmge, solution contamination (wig not
have reridus on ymts), iaahqem chsning sad
deoxidiziag. or over sealing could all cmmibum m cohesive
anodhu failme. Ahbough no smhce conmminants wcm
found. the fact that d» pmblem accused mmo an ~ymgled smfaces suggested duu tbe milling conuilxued to tbe
yrrdd cut
Conective Acdoa:
1. Inauyomtcd a shot peen dsconuun' atioa sssp (5mia
msx.)fm sll cbemicagy miged parts prior to sandhi
2. Men@i the seal mquhement Bu 85% ofsuodiz»dSuimed
commmcial bsrdwme.
Rezuhs:
Reject'om for paint sdheshm hss reduced by 80%.
Touch lip
Msterhdl 44QN-11 Water Rcducibh Epoxy Primer
Vendor. Deft
Boeing Spec'ficstion: BMS 10-117)q» I,Grade E
cup, d» primer would foam aher brush ~which was
unmcrquable. Ia tbe hue sprhg and nmuner mouths, dm
primar wss ahasdy nmhg up by dm dnm tbs opsrutru
tstaratri to tbe wotk stash' It nmst be noted brse that ti»
mdacdoa ia yot hfe at shunted uxnpenmura wst
dhcovenri dming d» msn~ trials ~during
dm imphnmamdca smdy. Tbe easiest cribs, however, were
mu idemiBcd emly enough dus to the emybssh ylaced h
couvmthg tbs nut)or paint sboya
Suspect Gmmr
l. ~the primer at elevate tsmpmauue oumgthms
Szddsally reduced d» pot life.
2. IBgh wmcr coatsat (150%ndacthm) ofpaint snd tyPe of
brushes anxL
Tesdng and Evslusdon:
1. Performed viscosity analysis at coauolled mom
tempurstme conditions to observe viscosity rise with
respect to thus
2. Coordinated with other Boeing Divisions on the foaming
pmbhm.
Rcmlcc
l. Visccsuy doubhxl fern 19to 36sccomh hmreea 55 -6
home st 72F using a Zebu ¹ 2 cup.
2. BMTmconimcnded ths following:
a) 75%rahcdon with water
b) use 4443N-57 Deft for a»eh-up oaly
c) uy diifmeat bmsbes ru Q-dps
d) uss csnridgc khz packaged by Counbsuhh
Conecdvc Actkxz
l. Insudled refrigemuus in sealant cribs to maintain
pmdution scceptsbh pot life.
2. Changed pmcess speciBcation to reduce d» water content
by 50%.
Results:
Achieved a workable pot life with rsrigsration sml
minimized foaming to acceptable levels by reducing water
contest and impmving syplicstion techniqueL
Pmbhm:
l. Extremely shat pot hfe shove SBFambient.
2. Foemhg ofyrimsr ahar bmsb sppliauioa.
Backgmuruk
Production demands nqaire an hnmedhm sapply oftoocbuy
(small) ~of mhed paint for Iocaliaed brush
zyygcsthm m suyyon ~These qoantitiss would be
mhed m nhuux» for emergemrsqohementz aad dhyconri
hom scahua cribs Bu wer sbopL Under normal conditions at
d» recotnmcuded viscosity of(IS - 22) ssc. in a Zabn ¹ 2
Material: 0343N-236 Fht Gn»a Polymethane
(Chemical Agent Reshumt Coathg)
Vendar. Deft
Muerial Spscidcsdoa: MIIA:-46168 Type IV
1706
10

11. Bschgtoumh
Bscemive gkss became evhhmt ader cme out oftbe
polytumhmm extcrhr topcoat oa tbe CH47 Chinook
seoptssan Tide b atejectsbb ccadhka shee dm cusuuucr
teqahemcat is for a Bm pskt sysusa. Paint tbkhnem
tidings oa dm cmed Blm wee tbkhcr dma tequhed
piculsrly in tbe paint overisp mess whom tbe gkss wss
most evident The veador was coumctsd m pmvide technkst
supp«L
Suspect Cause
Shat pot life cstsdng poor Bow~ tesuldug in inctmsismm
igm Ndaesa 'Ibk is congdtcsted by ibe escelhm "baog"
cbamcteristks ofdds psiat system alkwkg tbkh pskt Blms
to sdbme to tbe ah«alt whhout mns «"~As a msult, ~~occms in tbe ddcher areas,
psdculsriy whom tbe paint sppgcatica mcs overlap.
ZuhuSXEedg'
Implemcntsdcu ofthe fogowkg cauings for Pbam IIL
~ Dry Film Lubricant
~ Scale Inbgdt«
~ Adhesive Bomgng Primers
~ Ccmmendsl Bxterior Primae
Thc cstent of dus tdf«t, however, is condngsm upoa funue
retptimtneats in tbe upcomkg NBSHAPiCTG (Nsthmsl
Badsska Sumdmds for Hsssnkm Air polhasa~
~atdeelkes) whkb amy estsbgsh new duesholds
that sane ofdmse msnuials will meeL Odmr tff«ts to
increase paint usnsfsr cfdckscy with HVLP (High Volume
Low Pnusme) guns sad hnpmved spplksdcas ~are aimed st reducing seas aad envimamental ric, whge
g bigb tpudhy stsndsnla
'Ibe Helical Divisica ofthe Boring Drfeum sud Spare
Gmup Is ~to bciag pmsctive oa cnvinmmcaud
isstmn Tbe ocmpsay bss deuumsusted tbm cmnmttmsm by
to cbsgeagm whh a mum of mgeacy sad by
iavesdng dm msomctu seeded m devekp sad 'mplemeat
tdfecdve sobaknn
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