Objective:

The objective of this project is to demonstrate and validate an environmentally compliant Low Observable (LO) coating technology, as well as transition the material primarily to the F-35 and F-18 aircraft by tuning it for weapons-specific use. This project will demonstrate compliance with platform-specific performance requirements and assess transition costs for field implementation to the Unmanned Combat Air Vehicle (UCAV). It also will build an awareness of the technology in the LO community to ease transition to other platforms for all Department of Defense (DoD) branches through the LO Tri-Service Supportability Working Group.

Technology Description:

Through SERDP project WP-1181, which investigated low Volatile Organic Compound (VOC) radar absorbing materials (RAM), an environmentally friendly LO coating that met all of the DoD mechanical, chemical, environmental, and electrical property requirements was developed. The coating formulation contains less than 1% VOCs and contains no Hazardous Air Pollutants (HAP) or free diisocyanates. The formulation is a single component and does not decompose into environmentally noxious materials during storage for prolonged periods. Filled coating formulations were successfully cured under ultraviolet (UV) irradiation in thickness ranging from 1-4 mils. Multilayer application was successfully demonstrated up to 100 mils total thickness, and layers were found to be compatible and strongly bonded together.

In this project, the SERDP-developed coating will be tuned to weapon-specific requirements, and application and curing processes will be demonstrated. Through requirements definition, material tuning, and testing, weapon-specific performance requirements will be addressed. A field and/or depot demonstration consisting of spray application to radar test panels and confirmation of material meeting LO requirements will be conducted. Material production will be scaled up by selecting a material manufacturer and producing the material in 55-gallon batches. Equipment and processes will be optimized, including refinement of the UV cure lamps to be portable and development of cure procedures. Finally, the material application will be demonstrated on the F-35 aircraft.

Expected Benefits:

An environmentally friendly LO coating will eliminate a major source of hazardous material waste, reduce VOC emissions from the production and application of these materials, significantly reduce material disposal costs for aircraft maintenance, and increase safety for personnel involved in the application and removal of these materials. Successful implementation of the technology will result in a nearly 100% reduction in VOC emissions generated during the spray application of RAM coatings. Potential cost savings related to the elimination of VOCs are estimated to be between $9 and $30 million annually. (Anticipated Project Completion - 2007)

Principal Investigator:
Mr. Alan Fletcher
Air Force Research Laboratory
AFRL/MLSA, Building 652
2179 Twelfth Street, Room 122
Wright-Patterson AFB, OH 45433-7718
Telephone: (937) 255-7481
Fax: (937) 656-4419
E-mail: alan.fletcher@wpafb.af.mil