Occupational Safety and Health Administration (OSHA) studies have determined that hexavalent chromium poses significant medical risks to users. Hexavalent chromium is considered a potential lung carcinogen. Studies of workers in the chromate production, plating, and pigment industries consistently show increased rates of lung cancer. It has also been shown that direct eye contact with chromic acid or chromate dusts can cause permanent eye damage. Hexavalent chromium can irritate the nose, throat, and lungs and repeated or prolonged exposure can damage the mucous membranes of the nasal passages and result in ulcers. In severe cases, exposure causes perforation of the septum (the wall separating the nasal passages). It has also been proven that prolonged skin contact can result in dermatitis and skin ulcers. Some workers develop an allergic sensitization to chromium and kidney damage has been linked to high levels of dermal exposures.

While chromated systems (applied coatings and plated) have set the bar for treatment and protection of aluminum, it is now known that hexavalent chromium is carcinogenic and poses significant risk to human health. On February 28, 2006 OSHA lowered the 8 hour time-weighted average (TWA) Permissible Exposure Limit (PEL) for hexavalent chromium from 52 ΅g/m3 (micrograms per cubic meter of air) to 5 ΅g/m3. OSHA issued a deadline of May 31, 2010 for employers to comply with this PEL through the implementation of engineering controls. The final rule also includes provisions for employee protection such as preferred methods for controlling exposure, respiratory protection, protective work clothing and equipment, hygiene areas and practices, medical surveillance, hazard communication and record keeping. In the interest of worker safety, as well as the cost and operational implications of new and pending environmental, safety and health regulations, both NASA and the US Department of Defense (DoD) continue to search for alternatives to hexavalent chrome in applied coatings and plating applications that meet performance requirements in corrosion protection, cost, operability, and health and safety; while underlining that performance must be equal to or greater than existing systems.

Objective
Objective is to test promising coatings identified from Phase I of TEERM Non-Chrome Coating System Project (http://www.teerm.nasa.gov/projects/NonchromateCoatingSysFor Aerospace.html) and several new materials to additional stakeholder identified specifications. Overall objective of the TEERM Non-Chrome Effort is to evaluate and test a fully non-chromated coating system (pretreatment, primer and topcoat) as well as several pretreatment & primer only systems as replacements for hexavalent chrome coatings in aircraft and aerospace applications.

Period of Performance

• August 2008 to August 2010

Stakeholders
NASA Centers (Johnson Space Center, Kennedy Space Center (KSC), Marshall Space Flight Center (MSFC); Space Shuttle Elements/Prime Contractors; Constellation Program, Shuttle Environmental Assurance initiative, U.S. Air Force (Hill Air Force Base, Air Force Materials & Manufacturing Directorate and Wright Patterson Air Force Base Coatings Technology Integration Office), Navy & Army, ATK, Lockheed Martin, Northrop Grumman, Boeing, United Space Alliance, Raytheon and Spirit Aerosystems.

Benefits

• Meets environmental and safety regulatory requirements
• Reduces need to monitor for chromium exposure due to new regulations
• Decreased risk of environmental, worker and public exposure
• Reduced maintenance cost and government liability

• Test panels at Spirit Aerosystems in Wichita, KS undergoing 2000-hr salt fog on 2 alternatives and 1 control.
• Test panels received at MSFC for bare corrosion resistance testing (pretreated only)
• Adhesion Testing at Hill AFB Completed – June 18, 2009 – All Systems PASSED.
• Test Panels at the Beachfront Corrosion Test Facility and Launch Complex 39-B have been exposed for 5 months as of October 17, 2009 – All but two systems show NO signs of corrosion.
• JTP Final as of June, 18, 2009

Status: In Testing, still relatively early in project.

• Identified 200+ full coating system tests, 80+ pre-treatment and primer tests and 95+ pretreatment only tests that have been performed in researching historic non-chrome research / testing – October 2007 – March 2008
• Developed final draft of Joint Test Plan / Testing Approach – August 2008
• Pad test site setup – September 2008
• Began coordination / communication with Constellation Program regarding testing of non-chrome coatings – March 2008
• Began coordination with OEMs, DoD Agencies (Air Force, Navy) on coordinated testing – March 2008
• Completed initial draft Joint Test Protocol and initial draft Potential Alternatives Report, which recommended included the coating systems to be tested – March 2008
• Identified test sites for atmospheric and 2,000 hour salt fog test – May 2008
• Identified in-kind test site for bare corrosion resistance testing – August 2008
• Identified in-kind test site for adhesion testing – November 2008
• Initiated testing of Air Force coated panels at launch pad and beach test sites – November 2008
• Initiated testing of corrosion rate panels at pad – November 2008
• Three Systems from Phase I, 4 from Navy/DoD Testing and 1 Un-tested will be a part of this Hex-Chrome Free Coatings Project.
• Additionally Coatings (11 in total) from Ares and AF are a part of the project.
• JTP Draft Completed in October 2008.
• AF Coupons, some Ares Coupons and Corrosion Rate Coupons have been placed at test sites at KSC (November 2008)
• Completed test panel preparation guidance document with stakeholder approval – December 2008
• Everyone has their panels: Spirit, MSFC, Hill AFB, KSC
• Completed all Phase I Testing (Salt Fog, Cyclic Corrosion, Filiform Corrosion, Hydrogen Embrittlement, Adhesion (Patti Jr.), Dissimilar Metals)
• Ares Upper Stage Panels were shipped to KSC for Atmospheric Testing - March 2009.
• All panels have been painted and will be placed at the test sites or shipped to test facilities in April 2009.
• Galvanic Couples corrosion resistances were being prepared at MSFC and will be in place at KSC by July 2009.
• Complete Final JTP for Phase II (June 2009)
• Begin laboratory testing for Phase II (May 2009)

• Monitor progress of lab and atmospheric testing.
• Coordinate galvanic couple test panels and begin galvanic corrosion testing.
• Begin drafting coating performance report for salt-fog testing after initial data from Spirit becomes available.

·      + Reports