AFRL / ASC Deicing Research & Development Vision and Strategy

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1 AFRL / ASC Deicing Research & Development Vision and Strategy Dr. Elizabeth Berman, Mr. Vincent Johnson Air Force Research Laboratory, WPAFB, OH Ms. Mary Wyderski Aeronautical System Center, WPAFB, OH ACI-NA / ATA / RAA Deicing Management Conference 9 July 2009 Cincinnati, OH 1

2 Deicing Program Briefing Outline Problem Statement Air Force Vision Goals and Objectives Deicing Technology Portfolio Military Test Methods New Aircraft Deicing / Anti-Icing Materials & Processes New Runway Deicing Materials Bioremediation Projects &Techniques AFRL / ASC Deicing Teams Participation Summary

3 The Problem Icing on Aircraft and Runways Impacts Safety War Readiness Air Worthiness Environmental Safety and Concerns Costs Materials Compatibility Impacts Reliability 3

4 Deicing Materials Compatibility Concerns Current Deicing Materials have adverse effects on military and commercial aircraft materials. Examples include: Corrosion of aircraft parts Carbon brake deterioration Electrical connector shorting Infrared window damage Above damage is costly to both military and commercial aircraft Additional / New materials and process need to be tested Vendor / suppliers not necessarily testing to military requirements 4

Example of Corrosion Damage From Current Runway Deicing

failure rates are being seen in the forward facing units.

potassium acetate runway deicing materials.

and potassium has been detected in the corrosion areas.

5 Example of Corrosion Damage From Current Runway Deicing Materials LAIRCM (Laser IR Counter Measures) ISSUES High failure rates are being seen in the forward facing units. Corrosion seen on cadmium plated components exposed to potassium acetate runway deicing materials. Corrosion and water entrapment inside the unit is the problem and potassium has been detected in the corrosion areas. Some electrical system failures have been reported. (Provided by Boeing C-17) (Provided by Boeing C-17) 5

6 Air Force Deicing R&D Vision Look for single technology to deice runways and aircrafts Provide high performance runway and aircraft deicing product(s) to meet warfighters requirements Assess/reduce negative impact of deicing chemicals on weapon systems Reduce environmental impact from aircraft/runway deicing chemicals

7 Deicing R&D Goals/Objectives Provide material compatibility data beyond the commercial specification(s) on available/ developing deicing products to aircraft managers Materials compatibility testing on Aircraft Parts (i.e. lubes/ greases, cannon electrical plugs, coatings) Materials compatibility testing of new green aircraft deicing fluids Develop / transition / transfer new deicing and / or antiicing technologies for use on DoD weapon systems Green aircraft deicing fluids (ADFs) Green and less corrosive runway deicing chemical products Transportable and fixed infrared (IR) aircraft deicing facilities Small-scale, cost-effective transportable deicing fluid reclamation system Bioremediation of current hazardous deicing materials

8 AFRL / ASC Deicing Partnership ASC Establishes Deicing / Anti-Icing Requirements AFRL Develops and Executes Technical Programs to Meet Requirements

Joint Service Aircraft & Runway Deicing Test Protocol Joint Service Initiative Purpose: Determine specific test measurement methods on military unique materials across all DoD Gather AF, Army, Navy

9 Joint Service Aircraft & Runway Deicing Test Protocol Joint Service Initiative Purpose: Determine specific test measurement methods on military unique materials across all DoD Gather AF, Army, Navy Joint Test Protocol (JTP) deicing requirements Material compatibility testing beyond the commercial specification Maximize stakeholder acceptance of JTP Gather baseline & initial comparison materials test data, in accordance with the revised AF Material Test Method Standard (MTMS) Will be one standard evaluation program across all operational commands 9

10 Deicing Joint Test Protocol JTP Material Categories for Testing Metallic Materials/Unpainted Surfaces Elastomers & Sealants (including helicopter elastomeric bearings) Polymer Matrix Composites Infrared Window Materials Carbon-carbon Brake Materials Aircraft Wire Insulation High Velocity Oxygen Fuel (HVOF) Coating Lubricants/greases Low-Observable Coatings Low-Observable Sealants Cannon Electrical Plug Connectors Plastic Windows Painted Surfaces 10

11 Ice-phobic Clear-coat to Improve Aircraft and Pilot Safety Contract No. FA C-5601 Novel Phase Change Materials (PCM) with Anti-icing and De-icing Properties The PCMs undergo solid-solid phase changes resulting in small localized structural changes. PCMs create strain and stress at the ice-coating interface. Dramatic reduction in force required for removal of accreted ice. Novel Ice-phobic Coating Technology Durable permanent coating Hinders ice accretion Reduces ice-adhesion Deicing Process of epaint s PCM-based Ice-phobic Coatings

Ice-phobic Coating Test Results Ice-adhesion Testing (Based on ASTM D 3528-96) Low ice-adhesion comparable to sacrificial coatings Sample

Company at -4 0 C **Rain X mixed with MP-55 fine particle PTFE powder.

12 Ice-phobic Coating Test Results Ice-adhesion Testing (Based on ASTM D ) Low ice-adhesion comparable to sacrificial coatings Sample ID *Aluminum Control *MIL-PRF **Rain-X w/ PTFE *epaint PCM Peak Load (lbs) 235±47 240±50 51±15 7±2 *Prepared and Tested at epaint Company at -4 0 C **Rain X mixed with MP-55 fine particle PTFE powder. **Results from CRREL tested at C Super-hydrophobic non-wetting surface Achieved contact angle of 154 Method developed by US Army Corps. of Engineers CRREL Example of epaint PCM Super Hydrophobic Surface

13 Novel Aircraft Anti-Ice Coating Material Seashell Technology Creation & testing of novel coatings to minimize both ice accretion and adherence to military topcoat surfaces Utilizes the concept of an ultrahydrophobic lotus-leaf Is an overcoat to current A/C coating systems Compatible with existing A/C topcoats (MIL-PRF-85285) Applications include any structures where ice forms This includes fixed-wing aircraft, wind machines, roofs, and offshore structures. Must not alter existing A/C topcoat / coating system properties (i.e. optical props, color, surface smoothness) Seashell Technology is in Phase II of an Air Force SBIR project 13

14 Engineering Concept The Seashell coating is ultrahydrophobic and mimics the well-known Lotus leaf effect. Water droplets lying on the coating surface exhibit a contact angle greater than 150. When unfrozen water droplets strike the coating, the water droplets bead into spheres and roll off the coated surface at low sliding angles (<5 degrees).

15 Ultrahydrophobic activity to minimize water droplet adherence and adhesion strength Water droplet contact angle on original substrate coating and after coating with Seashell ultrahydrophobic coating.

Comparison of Ice Build-up on Modified and Non-Modified Surfaces Conclusion: (Panel B) There is no apparent ice formation on the ultrahydrophobic

16 Comparison of Ice Build-up on Modified and Non-Modified Surfaces Conclusion: (Panel B) There is no apparent ice formation on the ultrahydrophobic modified surface, whereas, (Panels C and D) significant ice build-up is observed on the unmodified Air Force topcoat painted aluminum substrate sample.

17 Measurement of Ice Formation in a Freezing Rain Chamber Icephobic Aluminum Topcoat

18 Ongoing Testing of Seashell Coatings Abrasion resistance coatings suitable for applicable to aircraft. Coating icephobic capability in real-world and icing wind tunnel environments. Coating longevity under a variety of conditions

19 Environmentally Benign Aircraft Anti-Icing and Deicing Fluids Based on Cost-Effective, Bio- Based Ingredients Partnership with Battelle Memorial Institute (lead agency), AFRL/ ASC, Army (CRREL), Navy (NAVAIR), Octogon, AMIL (University of Quebec) Maximize use of bio-based ingredients Typically less persistent in environment, less corrosive, and less toxic Reduction in carbon footprint based primarily on replacing petroleumbased PG as FPD Battelle patents and experience with use of bio-based polyols along with other polyols, as needed, for freezing point depression Use of superior, multi-functional additives Minimizes the number of additives and therefore corrosivity and toxicity Simplifies overall formulation chemistry Reduces manufacturing costs New Program Started in March

20 Description: Non-Fluid Transportable Aircraft Deicing System (Radiant Energy) Uses a series of portable infrared heaters to deice aircraft Leverages commercial technology developed and in place at Newark, NJ, NY-JFK, and Oslo, Norway airports Heaters are electrically powered System is portable on military A/C goes into mobility bins System is low cost & lightweight Benefits/Impacts: Reduces volume of anti-ice fluids (environmental pollutants) by 90% Elimination of costs associated with capturing runoff fluids Cost Avoidance: $10 - $200K per location (varies depending on local wastewater discharge limitations) 20

21 InfraTek Deicing System Radiant Energy 21

22 Aircraft Deicing Field Planned Demonstration Field demonstration of environmentally advantaged aircraft deicing fluid EcoFlo low biochemical oxygen demand Winter of at Bangor ANG, Maine 22

Environmentally Benign & Reduced Corrosion Runway Deicing Fluid Partnership with Battelle Memorial Institute (lead agency), AFRL/ ASC, Army (CRREL), Navy (NAVAIR), Octogon,

Transesterification of vegetable oils & other fats (Company proprietary polyol(s) & salts) Demonstration new RDF will: Be environmentally benign Reduces / eliminates hazardous

23 Environmentally Benign & Reduced Corrosion Runway Deicing Fluid Partnership with Battelle Memorial Institute (lead agency), AFRL/ ASC, Army (CRREL), Navy (NAVAIR), Octogon, AMIL (University of Quebec) Develop & evaluate novel chemistry to formulate RDF from inexpensive, bio-based raw materials Identified 2-3 runway formulations Transesterification of vegetable oils & other fats (Company proprietary polyol(s) & salts) Demonstration new RDF will: Be environmentally benign Reduces / eliminates hazardous potassium acetate Reduce corrosion of Cd-plated parts & carbon brakes Reduced cost RDF discharge/treatment Crude Material Received 2008 Top 100 Inventions Award from R & D Magazine Refined RDF 23

24 Runway Deicing Field Planned Demonstration Field demonstration of new runway deicing material Noncorrosive, environmentally advantaged Winter of at Wright-Patterson AFB 24

25 Bioremediation - Extend Aircraft and Aerospace Ground Equipment (AGE) Wash Intervals and Service Life Purpose Conduct a study to determine if the proposed bioremediation technique/process is effective at degrading salts/contamination Verify no negative impacts are generated by residual microbes left on the aircraft and AGE Approach Formulate test plan Task 1 Viability Study Task 2 Materials Compatibility Evaluation Conduct Task 1 - bioremediation process evaluation to determine effectiveness and viability If effective and viable, continue with Task 2 - materials compatibility testing of DoD-specific materials Report results Currently performing Viability on second batch

26 Purpose Bioremediation - Microbial Remediation of Aircraft Deicing and Anti-icing Compounds Subtask Purpose Determine if the proposed bioremediation process from Corrosion Prevention & Control, Inc. can successfully degrade propylene glycol deicing fluids Perform materials compatibility evaluations to verify that residual microbes do not affect aircraft parts Approach Formulate test plan Task 1 Viability Study Task 2 Materials Compatibility Evaluation Conduct Task 1 - bioremediation process evaluation to determine effectiveness and viability If effective and viable, continue with Task 2 - materials compatibility testing of DoD-specific materials Report results Currently performing Viability on 4 th batch

27 Bioremediation Demonstration of Microbial Remediation of Aircraft Deicing and Anti-icing Compounds Purpose Conduct a full-scale demonstration of the closed loop microbial bioremediation technology (3-6,000 gal. tanks & bio-reactor) at Maine Air National Guard Base, Bangor, ME during the winter and spring of 2009 Approach Plan the demonstration activities and formulate a demonstration plan Monitor the process conducting field and laboratory evaluations as needed Formulate demonstration report with input from CP&S and Maine ANG Currently attempting to start fourth batch

28 Aeronautical Enterprise Deicing Working Group Air Force with associate members including Army, Navy, Canadian Air Force, airframe contractors Goal: Provide war-fighter flying capability, while maintaining environmental compliance 28

29 AFRL / ASC Deicing Teams Participation Aeronautical Enterprise Deicing Working Group Monthly MAJCOM Field Support Meetings Society of Automotive Engineers Joint Service Forums Workshops / Conferences AFMC Deicing Workshops 2004, 2006, & 2009 (tentative) SERDP / ESTCP Annual Workshop Regular Meetings with Industry

30 Deicing / Anti-Icing Summary Vision Single technology to deice aircraft and runways Goals Provide environmentally benign products Performance comparable, if not better, than currently used materials Transition / transfer new materials / technologies to DoD weapon systems Multi-faceted Aircraft & Runway Programs in Process New deicing fluids Two Ice phobic coating projects progressing well Dem/Val s to Start on Two Runway and One Aircraft Deicing Fluids in Winter Additional Aircraft Deicing Fluid SERDP funded program starting Materials compatibility studies Infrared technology Joint Service Initiative Bioremediation of deicing fluids / solvents Well tied in to & integrated with the DoD and Commercial Deicing Community

31 QUESTIONS? Questions??

Deicing Challenges & Solutions. Mary Wyderski ASC/WWME December 1, 2010

Deicing Challenges & Solutions Mary Wyderski ASC/WWME December 1, 2010 Report Documentation Page Form Approved OMB No. 0704-0188 Public reporting burden for the collection of information is estimated to