Objective:

Conventional radar absorbing materials (RAM) are applied as high volatile organic compound (VOC) paints at thicknesses of up to 100 millimeters or more, depending on the specific application. Building coatings to these thicknesses is both labor and time intensive. A RAM application for an aircraft or missile often requires several hours and multiple work shifts to complete. These coatings typically contain VOCs and hazardous air pollutants (HAP) such as methyl ethyl ketone (MEK), methyl isobutyl ketone (MIBK), toluene, or xylene at levels as high as 600 grams per liter. Because of the relatively large coating thicknesses required, RAM applications may comprise a significant portion of a facility's overall emissions that are subject to National Emission Standard for Hazardous Air Pollutants (NESHAP) regulation. Furthermore, the continued use of these high-VOC/HAP processes presents significant logistical and safety requirements as well as relatively long periods of time for manufacturing and repair.

Technology Description:

This project will demonstrate and validate quick-curing RAM coatings in combination with cutting-edge spray technologies on multiple weapon systems. Equipment and coating manufacturing will be scaled to show that the coatings can be realistically produced and applied in production or repair scenarios. The CAAP Co. FP-212-R and Boeing RDR-20 resin systems will be tested on actual or mockup aircraft. The equipment development effort will maximize environmental benefits by evaluating plural mixing spray equipment and Hydraulically Assisted, High Volume Low Pressure (HA/HVLP) spray guns. The equipment and RAM coating scale-up and demonstration/validation tasks will facilitate the transition of the CAAP Co. FP-212-R resin and Boeing RDR-20 material to interested platforms.

Expected Benefits:

The demonstrated technologies will result in significant economic and environmental benefits, including decreased labor hours, reduced production and maintenance cycle times, 75 percent fewer VOC emissions, and mitigated material usage and waste generation. If these expected benefits are projected for 600 F-16s, 3,000 Joint Strike Fighters (JSFs), and 800 F/A-18s, a reduction of more than 400,000 pounds of VOC emissions along with 130,000 pounds of RAM coatings and cleanup solvents will be achieved over a period of one year. Implementation of this system also has the potential to save the B-2 program $3.88 million over a 5-year period for 21 B-2 aircraft. This is a 58 percent reduction in cost, stemming from a savings of $3.066M in labor, $800K for RAM coatings, and $14K in cleanup solvents.
(Anticipated Project Completion - 2006)