Integrity Integrity Service Service Excellence Excellence

Going Green – Embracing

Environmentally Friendly Technologies

for Tomorrow

Colonel Paul C. WaughDirector of Propulsion

03 Sep 09

Air Force Materiel CommandAir Force Materiel Command

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Propulsion Environmental Working Group

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AF Director of Propulsion Collaboration for

Advanced New Sustainment

Insertion

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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

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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 DoD

depots & weapon systems

PEWG = Pollution Prevention (P2)

• 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

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Obstacles to P2

• “Hard Sell” because benefits in distant future

• Optional

• Focus technology awareness versus insertion

• Neither amicable to industry interest nor a sources of innovation

Mission ImpossibleMissionMission ImpossibleImpossibleMissionMission ImpossibleImpossible

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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 DoD Joint Propulsion

Coordinating Committee (JPCC)– Reporting directly to the AF Director of Propulsion

• Assess PIB environmental issues

• Build technical & financial networks

PEWG Network

www.pewg.com

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StakeholdersPEWG Network

JALC

DoD Labs

SPD/SM

KC-135

B-52

Army

DSCR

NATO-RTO/AVT

76MXW

PEWG = DOP HazMat Management Subcommittee

Industry

(OEMs/Vendors)

309MXW

DLAJPCC

Fed Labs

ESTCP

SAF/IA

HQ AFMC/A5S/A4M

PSTWG & MRO&P

HLSHLS

Navy

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Funding Sources

• DoD Investments– OC-ALC, OO-ALC, ASC/ENV (GOCOs)– ESTEP, SERDP– FCT, DACP, STP, RTOC, SBIR, QRFP, S3C

• PMDs of military organizations– Acquisition Programs– MRO organizations (DoD depots & FRCs)– P2 Programs

• Industry, Federal and State cost sharing• Congressional adds

LeveragingLeveragingLeveragingLeveraging

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Bridging Technology “Ditch”

Technology Ditch

TRL 6 TRL 7

Plating - NLOS

Cr6 Coatings – LOS & NLOS

Solvents

OldDry Sprays

HVOF

SPD

Lasers

Net Shaping

Cladding

Peening

Welding

0 Cr6 Coatings

CERAL 3450

ODS Free

Benign Solvents

New

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• 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

Implementation Approch

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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)

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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 60db

327 ASW/YP• Strategic Materiel Recovery & Reuse Project

– 2 year “Proof of Concept”– Closed loop de-manufacturing process using field

scrap– Institutionalize

AFMC Current Projects

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AFMC Current Projects

SAF/IAP - Foreign Comparative Testing (FCT)• Qualify CERAL 3450

– Replace SermeTel W (Cr6)• 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)

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AFMC Current Project

Congressional Line items

• Qualify non-hazardous Super Alloy Coatings – Engines, Landing Gear, Actuators, Structural

Components– Reduces weight– Reduces chrome plating (CR6)– Increases durability

(Continued)

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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)

Suggested Need Areas

• Laser additive manufacturing technologies

• Coating removal processes w/out HAZWASTE

• DoD Strategic Material Recovery and Reuse closed-loop de-manufacturing processes

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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

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

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