DECEMBER 2009 FLIGHT AIRWORTHINESS SUPPORT 45 TECHNOLOGY E FAST N I Z A G A M L A C I N H C E T S U B R I A 5 4 T S A F JDUELCYEM2B0E0R7 2009 E N I Z A G A 405 M L FLIGHT A C AIRWORTHINESS I SUPPORT N H TECHNOLOGY C E T Introducing more eco-efficient S chemical treatments for aircraft structure 2 U Towards a chromate-free Airbus B François MUSEUX R Ralf THEILMANN I A Airbus new Auto Pilot/Flight Director TCAS mode 10 Publisher: Bruno PIQUET Enhancing flight safety during TCAS manoeuvres Lucas BLUMENFELD Editor: Paule BOTARGUES Page layout: Quat’coul Cover: A320 Family Air & Bleed Parts suspended on racks after TSA anodizing (courtesy of AEROLIA FRANCE) working group activities 16 Photo by Chromo Ouest From engineering to airline culture Authorization for reprint of FAST magazine articles should be requested Gilles JUAN from the editor at the FAST magazine e-mail address given below Customer Services Communications Claire AMSELLEM Tel: +33 (0)5 61 93 43 88 Fax: +33 (0)5 61 93 47 73 e-mail: [email protected] A300-600 Extended Service Goal Printer: Amadio Enabling longer lasting operation 22 FAST magazine may be read on Internet André DELANNOY http://www.airbus.com/en/services/publications/ Jean-Michel PASCUAL ISSN 1293-547 6 © AIRBUS S.A.S. 2009. 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F 1 MORE ECO-EFFICIENT CHEMICAL TREATMENTS FOR AIRCRAFT STRUCTURE - TOWARDS A CHROMATE-FREE AIRBUS Introducing more eco-efficient chemical treatments for aircraft structure Towards a chromate-free Airbus The future of the aircraft industry’s impact on the anticipating the future regulatory framework at the environment is paramount to Airbus, continuously earliest possible stage in design, rather than searching for more eco-efficient values, from the implementing reactive solutions, has proved to be first step of the design and throughout the aircraft’s the most appropriate response to the various entire life cycle (see figure 1). Airbus integrated growing environmental challenges. Therefore, eco-efficiency values into its core strategy and was Airbus has launched initiatives to progressively the first aeronautical company to obtain the ISO replace the most hazardous substances and proces- 14001 environmental certification for all its ses. This article introduces the Airbus roadmap for European Union (EU) manufacturing sites and replacing chromate containing materials and pro- product related activities. Proactive approach, cesses with more environmentally friendly ones. François MUSEUX Ralf THEILMANN Expert ACF Project Manager Materials and Technologies Engineering Structure Airbus Customer Services Materials and Processes 5 4 Airbus Engineering T S A F 2 MORE ECO-EFFICIENT CHEMICAL TREATMENTS FOR AIRCRAFT STRUCTURE - TOWARDS A CHROMATE-FREE AIRBUS Aircraft life cycle Inventing new best practices figure 1 to disassemble and recycle end-of-life Investing in research to aircraft design cleaner aircraft Optimizing aircraft operations Managing the and maintenance for enhanced supply chain environmental performance for a shared vision of environmental responsibility notes Mitigating the impact of manufacturing on the environment thanks Chromium is a chemical to cleaner technologies and processes element that has the symbol Cr and atomic number 24. It is a steely-grey, lustrous, hard metal Chromate usage that takes a high polish and has a high melting point. The name Among a number of initiatives in chromium trioxide, zinc and po- of the element is derived from that respect, the Airbus Chromate- tassium chromate), are often found the Greek word ‘chroma’ meaning Free (ACF) project aims to in numerous processes such as: colour; many of its compounds progressively develop new eco- • Surface treatment applications: being intensely coloured. efficient alternatives to all appli- - Chromic acid anodising, cations and processes using - Acidic etching (pickling), Hexavalent chromium refers chromates (see figure 2) and offer - Conversion coatings, to chemical compounds that these new solutions widely, - Hard chrome plating. contain the element chromium bringing an overall benefit • Painting and bonding processes: in the +6 oxidation state. Usually throughout the life cycle of the - External and internal painting, such compounds are chromium aircraft, including for maintenance - Bonding primer, trioxide or the chromic acid operations. - Sealants. or dichromic acid. Chromate salts • And other additional have a yellowish colour, The ACF project involves all applications: dichromate salts are orange. stakeholders and the milestones - Electrical and electronic Chromium VI compounds for elimination of chromates. applications. are a synonym for Chromium Comprehensive research studies Hexavalent: Cr(VI). have been conducted for years. The hazardous properties of these The ACF project was initiated in substances and the resultant 2006 to ensure that mature regulatory pressure for repla- alternative options and technical cement have recently reinforced ACF roadmap solutions be available for all the need to replace them with less Airbus programmes without hazardous substances. compromising technical perfor- figure 2 mance and quality. de For over 50 years, hexavalent cr ea se chromium has been used as o f c corrosion-inhibiting compounds hro ma with the protection of metallic tes us surfaces as one of its most e important applications. Thanks to chromates, the protection was ensured for the 30-year aircraft lifespan without compromising flight safety, even in extremely 5 4 severe conditions. Chromates T 2006 2007 2008 2009 2010 2011 S A (such as strontium chromate, F 3 MORE ECO-EFFICIENT CHEMICAL TREATMENTS FOR AIRCRAFT STRUCTURE - TOWARDS A CHROMATE-FREE AIRBUS The main They are already subject to a formal ban under the European regulatory Directive 2002/95/EC so called framework RoHS (Restriction of Hazardous Substances) for electronic and Numerous regulations in various electrical equipment, even if on- countries and regions now strictly board equipment is today excluded restrict the use, production, from the scope of RoHS. Stringent storage, elimination or marketing occupational health and safety of chromates. requirements also regulate expo- sure to these chemicals. Chromates In Europe, most of the chromates are already banned within the are considered as highly automotive sector. hazardous, with very high con- cerns according to the newly Since 2006, the new Occupational adopted REACH* European Safety and Health Administration regulation (EC n°1907/2006). (OSHA*) regulation introduced in Chromate compounds will the USA regarding hexavalent certainly be subject to formal and chromium, has considerably low- time limited authorization for ered the Permissible Exposure further use (sodium chromate has Limit (PEL) for airborne exposure recently been introduced in the inducing very strict controls of the REACH* candidate list by the exposure to this chemical. European Chemicals Agency). information * REACH (Registration, * OSHA Evaluation, Authorisation (Occupational Safety and restriction and Health Administration) of Chemicals The United States OSHA is an agency - EC n°1907/2006) of the United States Department This new regulation aims to improve of Labor. Its mission is to prevent health and environment protection work-related injuries, illnesses,