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Strategy and Roadmap Ver 2 1.Pdf Cadmium and Hexavalent Chromium Alternatives 5-Year Strategy and Roadmap, Contract # W9128F-12-D-0041 25 May 2016 3150 Fairview Park Drive South Falls Church, Virginia 22042-4519 Advanced Coatings 5-Year Strategy and Roadmap Executive Summary The Strategic Environmental Research and Development Program (SERDP) and Environmental Security Technology Certification Program (ESTCP) Weapons Systems and Platforms Program Area has developed a strategy to reduce use of cadmium (Cd) and hexavalent chromium (Cr6+) by 90% or more at Department of Defense (DoD) maintenance depots over the next five years. The strategy includes objectives, metrics, and actions to demonstrate how this reduction can be achieved. The strategy employs site demonstrations and leverages DoD resources to replicate processes across the DoD depot community. It also includes a recommended future path for success in the advanced coatings area. As part of this effort, installation-specific implementation plans were developed in coordination with Letterkenny Army Depot (LEAD), Fleet Readiness Center Southeast (FRCSE), and Oklahoma City Air Logistics Complex (OC-ALC). These efforts helped inform the strategy. These implementation plans track to the overall Advanced Coating 5-Year Strategy and Roadmap, consist with DoD’s strategic vision as it pertains to Cr6+ and Cd reduction. DoD processes that contribute to current cadmium and hexavalent chromium use and production, and potential alternatives are illustrated in Figure ES-1. DoD Processes Chromate Topcoats and Chromated Cadmium Stainless Steel Adhesives and Cadmium Brush Coatings Stainless Steel Chrome Plating Conversion Chrome Sealers Specialty Primers Plating Passivation Sealants Plating Removal Welding Coatings Coatings Rare Earth and TCP Conversion Zn-Ni Brush TCP Anodize Non-Chrome other Metal HVOF An-NI Plating Citric Acid Laser Removal Coatings Plating Sealers Consumables Primers Mag_Rich Shield Gas nCoPl AlumiPlate Boegel/Sol-Gel Sol-Gel FlashJet Primters Modification Trivalent IVD Aluminum PreKote Other Other Chromium Other DoD Process DoD Alternative Figure ES-1. DoD Cd and Cr6+ Process and Alternatives Cr6+ and Cd-reduction initiatives have been prioritized using a relative scoring methodology. Four metrics were utilized in the prioritization process: 1) Impact to Readiness; 2) Likelihood of Implementation; 3) Return on Investment; and 4) Impact to Goals. Each metric was scored based on qualitative measures. After scoring, reduction initiatives were grouped into tiers based on how essential the alternative process is to achieving the ultimate goal of the strategy. Advanced Coatings 5-Year Strategy and Roadmap ES-1 Tier 1 priority initiatives are critical to achieving Cr6+ and Cd reduction goals. These initiatives must be successfully implemented for reduction goals to be achieved. These initiatives typically impact other depots, and address similar critical usages, emissions, exposures, and/or waste streams at multiple locations. Tier 1 priority initiatives typically have a significant impact to readiness, though this is not always the case. The ten (10) initiatives considered Tier 1 priorities are: • Non-Chromate Primer on Aircraft OML • Non-Chromate Primer on Aircraft non-OML Surfaces • Non-Chromate Primer on Off-Aircraft Components and Commodities • HAP-Free, Non-Cr6+ Wash Primer • Alternative to Chrome Plating • Alternative to Cadmium Plating • Non-Chrome Chemical Conversion Coatings for Aluminum • Alternative to Cadmium Brush Plating • Alternative Coatings Removal Processes to Reduce Cr6+-Containing Waste Streams • Implementation of Engineering Controls for Stainless Steel Welding Operations Tier 2 priority initiatives are not critical to achieving DoD Cr6+ and Cd reduction goals, but these initiatives nevertheless address significant usages, emissions, exposures, and/or waste streams. These initiatives may impact similar processes at other depots, increasing their value and return on investment. Tier 2 initiatives typically have a moderate impact to readiness, and may also exhibit strong ROIs. The four (4) initiatives considered Tier 2 priorities are: • Non-Chrome Stainless Steel Passivation • Alternative to Dichromate Sealers in Anodizing Operations • Non-Chromated Coatings Removal Alternatives • Non-Chrome Consumables for Stainless Steel Welding Tier 3 priority initiatives are not critical to achieving Cr6+ and Cd reduction goals and address usages, emissions, exposures, and/or waste streams to a lesser degree than those identified in Tiers 1 and 2. Tier 3 initiatives have a minor impact, and in fact, may not warrant expending resources to implement them. Tier 3 initiatives are typically localized, impacting only a single location with little impact to readiness. The fourteen (14) initiatives considered Tier 3 priorities are: • Non-Chrome Chemical Conversion Coatings for Magnesium • Non-Chrome Sealants for Aerospace Applications • Non-Chrome Structural Adhesives for Defense Applications • Alternative to Dichromate Sealers for Brush Plating Finishes • Alternative to Dichromate Sealers for Black Oxide and Phosphate Finishes • Non-Chrome Aluminized Coating for Aircraft Engine Applications • Non-Chrome Anodized Dyes • Non-Chrome Conductive EMI Coating • Non-Cadmium Silk Screen Ink • Non-Cadmium Safety Paint Advanced Coatings 5-Year Strategy and Roadmap ES-2 • Non Chrome Desmutting/Deoxidizing Alternatives • Robotic Painting to Reduce Worker Exposure and Increase Maintenance Efficiency • Reducing Emissions and Exposure from Chromated Adhesives and Sealants • Reduction of Emissions, Waste, and Exposures Associated with Cadmium Brush Plating Most of DoD’s Cr6+ and Cd usage, emissions, exposure, and waste stream reduction goals can likely be met by leveraging and expanding ongoing or past initiatives. In fact, 90% reduction in Cr6+ and Cd usage can be achieved through implementation of Tier 1 priority initiatives alone, most leveraging ongoing work either within the DoD or Original Equipment Manufacturers (OEM). Advanced Coatings 5-Year Strategy and Roadmap ES-3 Definitions and Terms Term used in Report Meaning in this report Synonyms [Comment] Hexavalent chrome, Chromate Chromium compound in the hexavalent state Hex Chrome, hexavalent chromium, Cr6, CrVI, Cr6+ [not used to refer to trivalent materials] Chromate conversion coating Chromate treatment used passivate aluminum Chromate passivation, Alodine, and magnesium Passivate (hexavalent, trivalent, Surface treatment to reduce the corrosion rate conversion coating non-chrome) of aluminum, magnesium, stainless steels, etc. Sealer Treatment used to seal porosity in anodized, Chromate sealer, dichromate sealer phosphated, or plated surfaces. Sealant Material used to fill macro-scale gaps and gap filler porosity; typically an organic, polymeric material Wash primer Chemical treatment used for paint adhesion and corrosion protection, usually on steels Primer Organic coating used to improve paint adhesion and corrosion protection Specialty coating Coating used for unusual or low-volume [In this report it does not refer to low application observable coating] Coating removal Coating removal by any means – Mechanical, Stripping, depaint chemical, laser, etc. Brush plating Localized electroplating using a pad known as Stylus plating, selective plating a brush or stylus Chrome Plating Electrochemical deposition of a hard or Hard chrome plating, electroplated hard industrial chrome surface treatment chrome Advanced Coatings 5-Year Strategy and Roadmap i Table of Contents Executive Summary ES-1 List of Acronyms vi 1 Introduction 1 1.1 Background 1 1.2 Regulatory Drivers and Impacts 3 2 Problem Definition 5 2.1 Usage/Waste/Emissions/Exposures 6 2.2 Weapon Systems and Platforms 9 2.3 Processes 13 2.3.1 Chromated Primers 16 2.3.2 Chrome Plating 17 2.3.3 Cadmium Plating 18 2.3.4 Chromate Conversion Coating 18 2.3.5 Stainless Steel Passivation 19 2.3.6 Adhesives and Sealants 20 2.3.7 Cadmium Brush Plating 20 2.3.8 Chromate Sealers 21 2.3.9 Topcoats and Specialty Coatings 21 2.3.9.1 Ceral 34 21 2.3.9.2 TemperKote 1000 No. 23 Safety Red 22 2.3.9.3 Sermetel 22 2.3.9.5 Cho-Shield Conductive EMI Coating 23 2.3.9.6 Red Silk Screen Ink 23 2.3.10 Coatings Removal 23 2.3.10.1 Physical Coatings Removal 23 2.3.10.2 Chemical Strip 25 2.3.11 Stainless Steel Welding 25 3 Current State of Implementation 27 3.1 Alternatives 27 3.1.1 Chromated Primers - Alternatives 28 3.1.1.1 Alterative: Rare-Earth and Other Metal Primers 28 3.1.1.2 Alternative: Magnesium (metal) Rich Primers 29 3.1.2 Chrome Plating – Process Improvements and Alternatives 29 3.1.2.1 Alternative: High Velocity Oxy-Fuel (HVOF) 29 3.1.2.2 Alternative: Nanocrystalline Cobalt-Phosphorus 30 3.1.2.3 Alternative: Trivalent Chromium Electroplating 30 3.1.2.4 Alternative: Other 31 3.1.3 Cadmium Plating – Process Improvements and Alternatives 31 3.1.3.1 Alternative: Zn-Ni Plating 31 3.1.3.2 Alternative: AlumiPlate 32 3.1.3.3 Alternative: Other 33 Advanced Coatings 5-Year Strategy and Roadmap ii 3.1.4 Chromate Conversion Coatings – Process Improvements and Alternatives 35 3.1.4.1 Process Improvements 35 3.1.4.2 Alternative: Trivalent Chromium Process (TCP) Conversion Coatings 35 3.1.4.3 Alternative: Boegel/Sol-Gel 36 3.1.4.4 Alternative: PreKote 36 3.1.5 Stainless Steel Passivation – Alternatives 37 3.1.5.1 Alternative: Citric Acid Passivation 37 3.1.6 Adhesives and Sealants – Process Improvements and Alternatives 37 3.1.7 Cadmium Brush Plating – Process Improvements and Alternatives 38 3.1.7.1 Process Improvements 38 3.1.7.2 Alternative:
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