Transcript No Slide Title

Air Force Materiel Command
Going Green –
Embracing
Environmentally
Friendly Technologies
for Tomorrow
Colonel Paul C. Waugh
Director of Propulsion
03 Sep 09
Integrity  Service  Excellence
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Propulsion Environmental
Working Group
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
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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 Impossible
Mission
Impossible
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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
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PEWG Network
www.pewg.com
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Stakeholders
PEWG Network
JALC
DLA
SAF/IA
JPCC
DSCR
ESTCP
NATORTO/AVT
HQ
AFMC/A5S/A4M
PSTWG &
MRO&P
PEWG = DOP HazMat
Management Subcommittee
Army
HLS
Navy
76MXW
309MXW
SPD/SM
KC-135
B-52
Industry
(OEMs/Vendors)
DoD Labs
Fed Labs
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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
Leveraging
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Bridging Technology “Ditch”
New
Old
Plating - NLOS
Cr6 Coatings –
LOS & NLOS
TRL 6
TRL 7
Solvents
Technology Ditch
Dry Sprays
HVOF
SPD
Lasers
Net Shaping
Cladding
Peening
Welding
0 Cr6 Coatings
CERAL 3450
ODS Free
Benign Solvents
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Implementation Approch
• 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
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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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AFMC Current Projects
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
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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)
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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 [email protected]
• Present your science at Summer PEWG
meetings [email protected]
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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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