Air Force Materiel Command Going Green Embracing

Air Force Materiel Command Going Green – Embracing Environmentally Friendly Technologies for Tomorrow Colonel Paul C. Waugh Director of Propulsion 03 Sep 09 Integrity Service Excellence 1

Propulsion Environmental Working Group AF Director of Propulsion Collaboration for Advanced New Sustainment Insertion 2

PEWG Vision The Ultimate Green Engine A gas turbine engine designed and built so that the parts do not corrode or wear out during the period the engine is deployed. The engine contains no toxic materials, components and no hazardous substances are used/released during manufacturing, maintenance, repair, and overhaul of the engine. Engine operation should have minimal environmental impacts from noise and air emissions. Finally, valuable components and/or materials are recovered when the use period ends. Otha Davenport 1999 3

PEWG Mission • Work across Propulsion Industrial Base (PIB) to discover and insert safe, clean and effective manufacturing, maintenance, repair and overhaul (MRO) technologies – Performance: Increase Time On Wing – Affordability: Insert new engine technology into fielded engines – Competiveness: Infuse new technologies into Do. D depots & weapon systems 4

PEWG = Pollution Prevention (P 2) • Pollution prevention is reduction or elimination of pollution at the source instead of at the end-of-the-pipe or stack Versus • Environmental Management which is compliance with laws and making the operation manageable 5

Obstacles to P 2 • “Hard Sell” because benefits in distant future • Optional • Focus technology awareness versus insertion • Neither amicable to industry interest nor a sources of innovation Mission Impossible 6

PEWG Collaboration • Simple concept – organize and coordinate a PIB attack on environmental security and weapon system sustainment problems – PEWG is a mandated AF working group – Organized under the Do. D Joint Propulsion Coordinating Committee (JPCC) – Reporting directly to the AF Director of Propulsion • Assess PIB environmental issues • Build technical & financial networks 7

PEWG Network www. pewg. com 8

Stakeholders PEWG Network JALC DLA SAF/IA JPCC DSCR ESTCP NATORTO/AVT HQ AFMC/A 5 S/A 4 M PSTWG & MRO&P PEWG = DOP Haz. Mat Management Subcommittee Army HLS Navy 76 MXW 309 MXW SPD/SM KC-135 B-52 Industry (OEMs/Vendors) Do. D Labs Fed Labs 9

Funding Sources • Do. D Investments – OC-ALC, OO-ALC, ASC/ENV (GOCOs) – ESTEP, SERDP – FCT, DACP, STP, RTOC, SBIR, QRFP, S 3 C • PMDs of military organizations – Acquisition Programs – MRO organizations (Do. D depots & FRCs) – P 2 Programs • Industry, Federal and State cost sharing • Congressional adds Leveraging 10

Bridging Technology “Ditch” New Old Plating - NLOS Cr 6 Coatings – LOS & NLOS TRL 6 TRL 7 Solvents Technology Ditch Dry Sprays HVOF SPD Lasers Net Shaping Cladding Peening Welding 0 Cr 6 Coatings CERAL 3450 ODS Free Benign Solvents 11

Implementation Approch • Obtain buy-in – Cognizant weapon system, product and process engineers – Funding source(s) – Program Manager(s) • Fielded MRO operations – Maintenance practices – Repair methods – Overhaul process • New engine & component manufacturing – Component design – Industrial process 12

AFMC Current Projects 76 PMXG/QP & 639 ACSG/EN • Qualify Advanced Powder Coating Powders – Vanes • Qualify HVOF Coating Removal System – 15 engine components • Qualify Supersonic Particle Deposition – Magnesium Gear Boxes (continued) 13

AFMC Current Projects 76 PMXG/QP & 639 ACSG/EN • Develop requirements documents and specifications 10 & 13 meter Test Cell complex – Bio fuels – Stronger building materials (concrete) – Noise reduction 60 db 327 ASW/YP • Strategic Materiel Recovery & Reuse Project – 2 year “Proof of Concept” – Closed loop de-manufacturing process using field scrap – Institutionalize 14

AFMC Current Projects SAF/IAP - Foreign Comparative Testing (FCT) • Qualify CERAL 3450 – Replace Serme. Tel W (Cr 6) • Qualify Environmentally Controlled Coating Application Modules – Humidity & temperature, heat treat – Replaces open air spray booths • Qualify portable Hand Held Laser Welding – One time ABDR field level fixes – Replaces TIG welding • Qualify Advanced Plasma Spray Equipment – Triple Anode Axial feed system – Reduces material waste, increases efficiency (continued) 15

AFMC Current Project Congressional Line items • Qualify non-hazardous Super Alloy Coatings – Engines, Landing Gear, Actuators, Structural Components – Reduces weight – Reduces chrome plating (CR 6) – Increases durability (Continued) 16

Suggested Need Areas • Advanced “NLOS” spray technologies to replace tank based processes • Radiological coating disposal methodology • Non-Radiological thermal barrier coating to eliminate thorium • Transportable waste-to-energy equipment (continued) 17

Suggested Need Areas • Laser additive manufacturing technologies • Coating removal processes w/out HAZWASTE • Do. D Strategic Material Recovery and Reuse closed-loop de-manufacturing processes 18

Guidance for PEWG Projects • • Present evidence that project is TRL & MRL 7+ Indentify specific components that benefit Identify specific benefits that will accrue Provide information required by source of project funds • Nominate by contacting PEWG Program Manager James. Conklin@tinker. af. mil • Present your science at Summer PEWG meetings Bob. Bondaruk. ctr@tinker. af. mil 19

Food for Thought A vision without a task is a dream A task without a vision is drudgery. But a vision with a task can change the world. ---Black Elk A vision without a strategy is a prescription for failure A vision without action is called a daydream; but then again, action without a vision is called a nightmare. ---Jim Sorenson 20

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