Objective
Validate alternatives to aliphatic isocyanate urethane coatings for structural steel.  Successful completion of this project will result in one or more materials being qualified for use on support equipment, launch structures, test stands, ranges, and any other carbon steel structures at NASA and Air Force Space Command.

Period of Performance

• Jul-03 to Nov-07.

• Eliminates environmental, safety, and health risks associated with isocyanates
• Reduces environmental, safety, and health risks associated with use of coatings with high volatile organic content, hazardous air pollutants, and other hazardous materials.

• Project Summary Plan – Complete
• Joint Test Protocol – Complete
• Field Test Plan – Complete
• SSC Isocyanate Hazard Control Plan – Complete
• Potential Alternatives Report – Complete
• Draft Joint Test Report – Complete
• Draft Cost-Benefit Analysis – Complete
• Final Joint Test Report – Complete
• Final Cost-Benefit Analysis – Complete

• Based on the results of the testing, five alternative coatings systems were approved for Qualified Products List in the NASA technical standard NASA-STD-5008A, Protective Coatings of Carbon Steel, Stainless Steel, and Aluminum on Launch Structures, Facilities, and Ground Support Equipment (currently under revision).

• Kicked off project – July 2003
• Completed Project Summary Plan – August 2003
• Completed Joint Test Protocol – January 2005
• Completed Field Test Plan – January 2005
• Completed SSC Isocyanate Hazard Control Plan – July 2005
• Completed Potential Alternatives Report – May 2006
• Completed Phase 1 testing – December 2005
  • The results were reviewed and four of the eight coating system alternatives performed well enough to continue to Phase 2
  • Phase 1 testing requirements are shown in the table below
  
  

  Phase 1 Testing Requirements for Alternatives to Isocyanate Urethanes Project
  Test	Test Methodology	AF Requirement	NASA Requirement
  Pot Life (Viscosity)	ASTM D 1200	X	X
  Ease of Application (including DFT)	SSPC-PA-2	X	X
  Surface Appearance (including color and gloss)	ASTM D 523; ASTM D 2244	X	X
  Dry-To-Touch (Sanding)	None	X	X
  Accelerated Storage Stability	ASTM D 1849	X	X
  Cure Time (MEK Solvent Rub)	ASTM D 4752	X	X
  Solvent (Acetone) Rub	ASTM D 4752		X
  Cleanability	MIL-PRF-83282 D; MIL-PRF-85285		X
  X-Cut Adhesion by Wet Tape	ASTM D 3359; FED-STD-141	X	X
  Tensile (Pull-off) Adhesion	ASTM D 4541	X	X
  Knife Test	FED-STD-141	X

  
  
• Completed Phase 2 testing – January 2007
  • Four alternative coating systems were carried on to Phase 2
  • Phase 2 testing requirements are shown in the table below
  
  

  Phase 2 Testing Requirements for Alternatives to Isocyanate Urethanes Project
  Test	Test Methodology	AF Requirement	NASA Requirement
  Removability	ASTM G 155	X	X
  Repairability	ASTM D 523; ASTM D 2244; ASTM D 3359	X	X
  Abrasion Resistance	ASTM D 4060		X
  Gravelometer	ASTM D 3170	X
  Fungus Resistance	ASTM D 3359; MIL-STD-810 F		X
  Accelerated Weathering	ASTM D 523; ASTM D 2244; ASTM G 155	X	X
  Mandrel Bend Flexibility	ASTM D 522	X
  18-Month Marine Environment	ASTM D 610; ASTM D 714; ASTM D 523	X	X
  Cyclic Corrosion Resistance	GM 4465 P; GM 9540 P	X	X
  Hypergol Compatibility	KSC MTB-175-88; NASA-STD-6001	X	X
  LOX Compatibility	ASTM D 2512; NASA-STD-6001		X

   
• Completed Field testing at Stennis Space Center - September 2006
  • All eight alternative systems and two control coatings were applied to an engine test stand at Stennis Space Center, Mississippi
  • The coatings were evaluated at 6 and 12 months
  • Field testing requirements are shown in the table below
  
  

  Field Testing Requirements for Alternatives to Isocyanate Urethanes Project
  Test	Test Methodology	AF Requirement	NASA Requirement
  Ease of Application (including DFT)	SSPC-PA-2	X	X
  Surface Appearance (including color retention and gloss)	ASTM D 523; ASTM D 2244	X	X
  Dry-To-Touch (Sanding)	None	X	X

  
  
• The results from this project were incorporated into the Low VOC Coatings and Depainting Technologies Field Testing Phase 2 (http://www.teerm.nasa.gov/projects/LowVOCCoatings_DepaintingTechFieldTestPh2.html) project – January 2007
• Briefed project at the Air Force Corrosion Conference in Macon, GA - March 2007
• Distributed Final Joint Test Report – August 2007
• Distributed Final Cost-Benefit Analysis – October 2007

• Assist in implementation of technologies at Stennis Space Center, other NASA Centers, and Air Force Space Command
• Brief the 18-month Marine Exposure Testing at the 2008 NACE Corrosion Conference – March 2008

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