3M AVIATION WINDOW RESTORATION SYSTEM by CLEARFIX AEROSPACE. Matthew Kelley / 3M Defense

Transcription

1 3M AVIATION WINDOW RESTORATION SYSTEM by CLEARFIX AEROSPACE Matthew Kelley / 3M Defense

2 Problem Statement Most aircraft windows are Acrylic or Polycarbonate Windows are easily scratched and hazed Potential Safety problem if left unfixed Down-time Cost Inability to see in all conditions Aircraft unavailable due to maintenance $ to replace windows, including labor Budget constraints Inventory control of multiple windows Access to maint, facilities is limited

3 Location of Windshields/Windows Overhead Window Center Windshield Crew Door Jettison Window Cabin Jettison Window Lower Window Cabin Door Jettison Windows Gunners Windows File: NAVAIR Brief 3

4 SOLUTION 3M/Clearfix Aerospace developed a patented polishing repair & coating process for stretched acrylic plastic windows (MIL-P NAVAIR H-60 Fleet Support Team is working to field it. Repair restores optical clarity. After polishing a UV coating is applied and cured. All windows polished and coated in place except crew door windows, which are easily removed. Various scrapped H-60 windscreens (LH and RH windshields, center, chin bubbles, and greenhouse) were provided to the vendor by NAVAIR to practice and perfect the process.

5 Product Overview

6 Product Overview Step Product Function 1: Mask up Masking Tape & Drapes Contain slinging & unwanted substrate contact 2: Clean Clearfix Cleaner & Microfiber Wipes Remove dirt before first buffing step 3: Polish 1 Clearfix Polish 1 & Yellow Pad Remove haze and small scratches 4: Clean Clearfix Cleaner & Microfiber Wipes Remove buffing compound 5: Polish 2 Clearfix Polish 2 & Gray Pad Optics Restoration. 6: Clean Clearfix Cleaner & Microfiber Wipes Remove buffing compound 7:Heat Surface Heat surface prior to Applying Clearfix UV Coating 8: UV Coating Clearfix UV & Microfiber Applicator UV protective coating 9: Heat Coating Gently heat to dry surface after application 3M Confidential

7 Suggested Kit Components File: NAVAIR Brief 7

8 Kit Concept Example Kit (includes consumable materials and support equipment) ~ $2500 to $3000 Support Equipment: Infrared Thermometer Polisher Heat Gun Required support equipment may already be available at work sites Consumable Materials: Polishes Spray Cleaner Large Polishing Pads Small Polishing Pads Backing Plates Microfiber Towels 8

9 Visible Results from Using 3M/Clearfix BEFORE AFTER Typical in service haze reading on H60 side transparency chin bubble was 36 on samples measured. Post refinishing haze reading approximately 1.5

10 Before Repair After Repair File: NAVAIR Brief 10

11 Extends service life of window. Removes scratches. Benefits of Using 3M Clearfix Aerospace Restores clarity with no distortion or hazing. Reapplies UV coating. Removes less amount of material from window compared to sanding & other polishing processes. Safety is enhanced by better vision through windows. Less costly and time consuming than replacing windows. Product is quick and easy to use. Products are safe to apply for both user and aircraft windows. Preventative maint. on a regular basis will maintain clarity of windows. No downtime after refinishing. Has potential to save the Navy millions of dollars annually. 11

12 NAVAIR Cost Savings - (Repair vs. Replacement of H-60 Windows) * Labor: Replacement*: 4-6 man-hrs./ window vs. 3M Clearfix Repair of min. / window. Savings using 3M Clearfix Aerospace = Approximately 95.8% Material: Replacement: total cost + $35,000 per aircraft. ($ to +$16, / window) 3M Clearfix Repair: total cost ~ $500 per aircraft. (Approximately $53.00 / window) Support Equipment: Infrared Thermometer ~ $175 (Needed for UV Coating application (D- & O-level) Heat Gun ~ $225 (Needed for UV Coating application ( D- & O-level) Polisher ~ $300 (Needed for Polish application (D-level only) Consumable Materials: Polishes ~ $65 / packet, Spray Cleaner ~ $15 / bottle Large Polishing Pads ~ $17 / pad, Small Polishing Pads ~ $5 / pad Backing Plates ~ $5 / plate. Microfiber Towels ~ $1.50 per towel *Cost savings figures per NAVAIR estimates. *Savings using 3M Clearfix Aerospace = Approximately 89.4% to 99.67% (per window) *Replacement time does not include sealant cure time of approximately 24 hours 12

13 Limitations and Product Use Precautions De-icing fluid will take off the UV coating (Step 3). The H53 forward windscreen is a polycarbonate laminate sandwich with heating element in between, do not use on this window The H60 two forward outer windscreens are glass; the 3M Clearfix system is not designed for use on glass. As-cast or Cast Acrylics, this type of acrylic becomes crazed from the UV coating (Step 3). Chemical substrate compatibility, review with the customer before using Isopropanol based cleaners REMOVE the UV coating, only use the Clearfix cleaner spray Review the directions for use Adhesion to hard-coated polycarbonate is poor This product is NOT erosion protection, the abrasion resistance is the same as you would have from uncoated Polycarbonate. The good news is many times the hazing or small scratches are contained within the UV coating. Simply remove the UV coating with Isopropanol and reapply the UV coating.

14 Testing at PAX NAVAIR PAX River Materials Lab sponsored testing of 3M Clearfix Aerospace. On 12 January 2012, 3M Clearfix Aerospace polishing restoration process was approved for all H-60 aircraft. Sole issue found during testing involved UV coating. Test panels with 3M Clearfix Aerospace UV coating showed signs of discoloration after 500 hours of weatherometer testing (no signs of discoloration after 250 hours). Section of test panel not treated with UV coating (but with Parts 1 and 2 of restoration process) showed no evidence of discoloration. H-60 Fleet Support Team feels that the benefits of the UV coating warrants its usage. Improved optical clarity over using polishing alone. UV coating will be further evaluated on operational aircraft. 14

15 Technology Deployment Incorporate HAZMAT on all FRC & squadron Haz-Mat Auth. Usage List (HAUL). Provide Logistics with components of kit for NSN development. Provide training to all FRCs and squadron personnel pending UV coating approval. 3M will provide FRC training & certification certificates at no cost to gov t. Certified personnel will be able train others. CNATTU lead CONUS training w/ asst. from 3M Initially, repairs will be performed by depot-level during Planned Maintenance Interval (PMI) and In-Service Repair (ISR). Develop Engineering Disposition (ED) for Depot-level polish repair procedures pending development and incorporation of work package for the Depot Structural Repair Manual A1-H60BB-SRM-100. Pending UV coating approval - Develop Interim Rapid Action Changes (IRACs) for H- 60 Interactive Electronic Technical Manuals (IETMs) to provide Organizational-level repair, inspection, preventative maintenance and cleaning procedures. Pending UV coating approval - Develop MRCs for inspection of windows. Grading criteria will be located in IETMs inspection requirements. 15

16 Project Team Participants NAVAIR H-60 Fleet Support Team NAVAIR Materials Engineering Division NAVAIR PMA 299 NAVAIR FRC s NAVAIR CNATTU Clearfix Aerospace 3M Aerospace

17 BACK UP SLIDES

18 There is a critical shortage of rotary aircraft in the armed forces. A major contributor is damaged windows. It takes 55 hours and in excess of $50,000 to replace 10 windows in a H60 Seahawk. You could repair windows in place rather than replacing them, saving 75% downtime and in excess of $40,000 per helicopter. 3M Clearfix, Practical, Safer, Faster. 3M Confidential NAVAIR is currently qualifying the 3M Clearfix solution. Increased operational readiness, enhanced pilot safety, while pioneering a DoD Enterprise Solution savings program in excess of $100MM

19 FAQ s Q How often does it require refinishing? A Depends on UV exposure but you might see some white streaking at 4 months after significant UV exposure. Q How much abrasion resistance does it have? A This product is NOT erosion protection, the abrasion resistance is the same as you would have from uncoated Polycarbonate. Q What resistance does it have in terms of cleaning fluids? A Avoid Isopropanol based cleaners and only use Clearfix Cleanser Spray Q What tooling is required to perform the process? A Electric buffer /or drill, heat gun and IR thermometer, called out in DFU S Q What Military, OEM or other approvals does the 3M/Clearfix system have? A None at this time, expecting a Navy approval to use the system on H60 helicopters soon.

20 20

21 Technical Collateral Directions for Use 4 MSDS Documents for System 4 Boeing D External Cleaner and Polish Test Docs Documents above available upon request Technical Data Sheet is coming

22 NAVAIR Damage Limits Allowable Damage in Noncritical Area from A1- H60BB/FB/HA/SA/RA-SRM-000 Center Windshield and Window Panels Minor scratches or abrasions no deeper than inch. Allowable Damage in Critical Area No cracks allowed Crazing that does not seriously degrade pilot/copilot visibility. Scratches no deeper than inch any length. Damage greater than allowable limits, damage causing poor visibility through window, or damage which prevents secure attachment of panel to frame, requires replacement of window panel.

23 NAVAIR Present Instructions for Cleaning Transparent Panels Flush surface of panel with clean water to remove loose particles of grit. Mix solutions of aircraft cleaning compound, P/N MIL-PRF-85570, Type I or II and clean water (1 part aircraft cleaning compound in 9 parts water). Apply cleaning solution to panel with soft, clean flannel cloth and use bare hands for washing operation. Flush off any grit felt under fingers to prevent scratching panel surface. If oil or grease film remains on surface, lightly wipe panel with a flannel cloth moistened with aliphatic naphtha. Blot surface gently until oil or grease is removed. Naphtha, P/N TT-N-95, will evaporate without leaving a film. Apply plastic cleaner with flannel cloth. Polish, P/N P-P-560, with light circular motion until panel is clean. Wipe off and final polish with another clean flannel cloth.

24 Contacts Brian Kenady, Exteriors Marketing Supervisor 3M Aerospace and Aircraft Maintenance Dept. 3M Center, St Paul, MN Office /Mobile Steve Falteisek, Technical Specialist 3M Aerospace and Aircraft Maintenance Dept. Application Development Engineer,MRO FAA A/P Licensed Technician 3M Center, St Paul,MN Office Cell Steve C. Stickels, Technical Service Specialist 3M Aerospace & Aircraft Maintenance Division 3M Center, 209-1C-31 St. Paul, MN Office: Fax: John K. Farrell H-60 Senior Subsystems Engineer AIR Cherry Point, NC Comm: (252) DSN: ISSC Cherry Point Products and Services: Denny E. Morris Senior H-60 Aerospace Engineer H-60 Air Vehicle Engineering Structures ISSC Cherry Point, NAS NI Det. Phone/Fax: (619) DSN: