Organic Protective Coatings and Application Technology

PACIFIC NW POLLUTION PREVENTION RESOURCE CENTER
POLLUTION PREVENTION RESEARCH PROJECTS DATABASE

Project Title: Organic Protective Coatings and Application Technology

Date Last Updated: 11/96

Project Summary: Organic coatings are the primary source of protection against environmental degradation for Navy aircraft, weapon systems and ground support equipment. These protective coatings contain toxic inhibitors (i.e. lead, chromates, etc.) and high VOC contents; these components are released during painting operations as organic and toxic air emissions. The goal of this project is to conduct a full spectrum approach for reducing the VOC and air toxic emissions from protective coatings. The development of non-toxic, VOC compliant coatings will enable the Navy to meet current and future environmental regulations as well as reduce the total amount of hazardous waste the Navy generates. In addition, these new materials will eliminate the need for the installation of extremely expensive control equipment (i.e. $1-5 million per spray booth for VOC emission control).

A full spectrum approach for reducing the VOC and air toxic emissions from protective coatings is being pursued. Investigation in low VOC polymer technology has been used to produce low VOC binder systems. Reactive monomers and diluents have been developed to obtain low viscosity, low VOC binder systems for future organic coatings. In addition, recent advances in water-borne resin technology have allowed the development of a high performance water-borne topcoat which goes beyond mere compliance with environmental regulations. Coating corrosion resistance, physical performance properties and VOC content were evaluated to develop the best materials. Furthermore, low/no VOC protective coatings (such as electrocoatings, powder coatings, bearing adhesives, 100% solids coatings, 100% water-based coatings, etc.) are also being researched for potential aerospace applications.

Several recently developed VOC compliant, non-toxic alternative materials have been investigated for this program. These compliant coating systems include compliant lacquer topcoats and non-toxic inhibitor systems. The non-toxic inhibitor systems were used to formulate replacements for the current lead and chromate containing materials. These new materials will be optimized, service evaluated and implemented for Navy use. Finally, conventional air spray equipment used to apply these materials, has a transfer efficiency of only about 28%. Therefore, implementing high transfer efficient spray equipment would significantly reduce the amount of air emissions from painting operations. Application equipment such as air-assisted airless, electrostatic, and high volume low pressure (HVLP) wave been evaluated and HVLP spray guns are being implemented in naval aviation facilities.

Project Keywords: organic coatings, materials substitution, paint application equipment, VOCs, low VOC polymers, non chrome/lead coatings

Organizing Performing Research: US Navy -- Naval Air Warfare Center Aircraft Division

Primary Research Contact:
Kevin Kovaleski
Naval Air Warfare Center Aircraft Division Patuxent River
434100A M/S 3 Bldg 2188
Patuxent River, MD 20670-5304
Phone (301) 342 8049
FAX (301) 342 8062
INTERNET: KOVALESKI_KEVIN%PAX5@MR.NAWCAD.NAVY.MIL

Anthony T. Eng
Naval Air Warfare Center Aircraft Division Patuxent River
Code 434100A, Bldg. 2188, M/S 3
Patuxent River, MD 20670-5304
Phone (301) 342 8067
FAX (301) 342 8062
INTERNET: ENG_ANTHONY%PAX5@MR.NAWCAD.NAVY.MIL

Date research Started/Completed: 9/92 - 9/98

Publications Based on Research: none available

Approximate Project Budget: $1,881,000

Primary Project Funder: Strategic Environmental Research & Development Project (SERDP)

Funder Contact:
Dr. Robert Holst
Program Manager for Compliance and Pollution Prevention
SERDP Program Office
901 North Stuart Street, Suite 303
Arlington, VA 22203
phone: (703) 696-2125
fax: (703) 696-2114
e-mail: holstrw@acq.osd.mil