If you’ve ever been to an Air Force air show, you would have
seen the PC9/A aircraft at its aerobatic best. These impressive planes are
famous for their mid-air flips, twirls and of course their shiny red coats.
Training Aircraft Systems Program Office (TASPO) is
responsible for their upkeep, and a recent improvement to the way their paint
finish is maintained has not only enhanced the efficiency of maintenance
procedures for this aircraft, but has also provided the DMO workers responsible
for delivering these sustainment services with a safer working environment.
Hexavalent Chromium is widely used in aircraft surface
finishing products due to its superior corrosion preventative properties.
Prompted by the detection of Hexavalent Chromium exposure to
PC9/A maintenance staff and facilities, TASPO got together with the Defence
Science Technology Organisation (DSTO) and the PC9/A’s Original Equipment
Manufacturer (OEM), Pilatus, to nut out an alternative to the existing
corrosion control process.
Although Hexavalent Chromium-free products are on the
market, TASPO and its partners could not establish the existence of a holistic
Hexavalent Chromium-free painting system.
The challenge was therefore to develop a system that
protected workers from Hexavalent Chromium during all three stages of the
corrosion maintenance process; pre-treatment, primer application, and topcoat
application.
The team sought a solution that used existing commercial
products so that development time could be reduced and a cost effective
painting method could be delivered in the quickest possible time.
Two different painting systems were identified as potential
solutions; the only difference being the product used for surface
pre-treatment, with one containing a safe form of chromium and the other being
chromium-free.
On-aircraft trialling of the two systems commenced in May
2012 and two PC9/A aircraft were fully repainted; one for each application
method.
The surface condition of these two trial aircraft will be closely
monitored over the coming months to ensure that both systems maintain the required
surface finish and corrosion preventative qualities.
A significant outcome from this program has been the
development and implementation of an innovative tool for the safe stripping of
painted surfaces.
Working closely with the OEM and the sanding equipment
manufacturer to develop a suitable technical solution, TASPO was able to
introduce the ACE 1000 Clayton pneumatic vac-assisted sanding unit to PC9/A
painting facilities.
This story first appeared in the DMO Bulletin.