Objective: The objective of this project is to demonstrate/validate the reliability of an Infrared-Reflectance Non-Destructive Inspection (IR2NDI) technique, developed under SERDP project WP-1137, to detect corrosion under typical aircraft and ground system coatings. Non-destructive inspection for corrosion through coatings will help to prevent pollution created from needless toxic waste and air emissions generated from paint stripping and re-painting operations. Technology Description: The IR2NDI technique takes advantage of an optically transparent spectral band that is found, in most coating systems, within the mid-infrared (IR) range of the electromagnetic spectrum. Since corroded surfaces do not reflect IR energy as well as the non-corroded surfaces, the signal is suppressed for the corroded surfaces or areas and results in a readily discernable and detectable dark area on a monitor or LCD screen. The advanced IR spectral imaging camera system (hardware and software) will be optimized and performance boundaries established with feedback from both laboratory and field measurements. Spectral analysis of actual service coating systems will be made to identify compatibility of camera configurations with pre-corroded laboratory standard specimens. Field measurements also will be made prior to stripping assemblies and parts so as to demonstrate and validate the IR2NDI technique under actual field conditions. Expected Benefits: The IR2NDI technique will target and map specific areas that require maintenance due to corrosion, allowing for a migration from schedule-based to condition-based maintenance. It will significantly reduce pollution and costs by eliminating unnecessary coating stripping/recoating. This project will establish the reliability of the technique and the cost and environmental benefits to depot and field maintenance operations. Expected environmental benefits to the Department of Defense (DoD) include an estimated reduction of 50,400 pounds (lbs) of volatile organic compounds (VOC) per year and a reduction of 720 lbs per year of carcinogenic chromates, when fully implemented with an extended life topcoat system on a cargo aircraft. This assumes a fleet of 180 aircraft and that the coating life is extended by just one year from a five-year de-paint/paint cycle to a six-year cycle, with 36 aircraft per year being processed. After successfully demonstrating this new technology, depot and field maintenance personnel will have an additional method to inspect for corrosion while minimizing the removal of coating systems. (Anticipated Project Completion - 2008) Principal Investigator:
Mr. Jack Benfer
Fleet Readiness Center Southeast
101 Wasp Street, Code 733
Jacksonville, FL 32212
Telephone: (904) 542-4516
Fax: (904) 542-4523
E-mail: john.benfer@navy.mil
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