Touch-N-Prep Alodine Pen Implementation At Boeing St. Louis

Februar

2003

Volume 8, Number 1

ENVIRONMENTAL TECHNOTES

ENVIRONM ENTAL

ASSURANCE

Touch-N-Prep Alodine Pen Implementation At

Boeing St. Louis: Lessons Learned

Boeing-St. Louis has implemented a new method to apply chemical conversion coatings on aluminum

and aluminum alloys. This new method involves the use of an applicator pen called Touch-N-Prep

Alodine 1132, manufactured by Henkel Surface Technologies, Madison Heights, Michigan. The pen is a

special felt tip marker that contains the Alodine 1132 conversion coating solution and works like a

highlighter pen, making it very user friendly (See Figure 1). The pen has several noteworthy advantages

over the other application methods such as spray, brush, and immersion.

Conversion coatings are important and serve

several purposes. When the conversion coating

solution is applied to aluminum, it converts the

oxide on the aluminum to a chromium/aluminum

oxide. This newly formed chromium/aluminum

oxide layer provides increased corrosion

resistance and improves paint adhesion. This

oxide layer also provides a conductive corrosion

resistant film for electrical bonding and

grounding applications where low electrical

contact resistance is required.

Figure 1 - Touch-N-Prep Alodine 1132 Pen

There are two important military specifications

that are used for specifying conversion coatings.

MIL-DTL-81706 covers the requirements for the

chemical materials used in the formation of

conversion coatings by the reaction of the

material and the surfaces of aluminum and

aluminum alloys. This specification does list the

applicator pen as an option under methods of

application. MIL-C-5541 covers the requirements

for chemical conversion coatings formed by the

reaction of chemical conversion materials (MIL-

DTL-81706) and the surfaces of aluminum and

aluminum alloys. Boeing Process Specification

(PS) 13204, Conversion Coating, Brush and

Spray, is also important. This specification

establishes the requirements and procedures for

conversion coating metal substrates with

chemical conversion materials in accordance with

MIL-C-5541. PS 13204 has recently been

revised, and is approved, to add the Touch-N-

Prep Alodine 1132 pens as an option to apply

conversion coating solution.

The Touch-N-Prep pens have the distinct

advantage of a 24-month shelf life over all other

methods of applying conversion coating per PS

13204. Conversion coating application methods

such as spray, brush, and immersion typically

have a 12-month shelf life. However, when a

thickening agent, Cab-O-Sil, is added to the

conversion coating solution to create a

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thixotropic solution, (the Cab-O-Sil material

increases the viscosity of the solution and

minimizes dripping and flow when applying the

conversion coating solution to surfaces oriented

in a vertical position), the shelf life is only 21

days.

Other advantages for using the Touch-N-Prep

pens include: reduced operator exposure to the

conversion coating solution, logistics advantages

such as in field repair to aircraft, reduced labor

time, and the elimination of hazardous waste

being generated. This elimination of hazardous

waste and reduced labor are significant

advantages. Even though the Touch-N-Prep pens

cost more than the old brush-on method, a cost

savings analysis estimate showed an approximate

savings of $250,000 for the first year of pen

usage at Boeing St. Louis.

The other methods of applying conversion

coating solution require excess solution to be

rinsed off with water and blotted up with a cloth

because it contains hazardous chromic acid. The

brushes and the cloths must then be disposed of

as a hazardous waste because they contain a

chromium compound. The rinse water is also

considered a hazardous waste and must be treated

as such. Applying conversion coatings using the

Touch-N-Prep pens does NOT require any

rinsing or wiping. The solution simply dries in

place. Therefore, there are no brushes, rinse

water, or cloths, which need to be disposed (See

Figure 2).

Alodine 1132 is similar to the other conversion

coating materials because it contains chromates,

which are hazardous materials. Therefore, proper

precautions, such as the use of appropriate

personal protective equipment, need to be taken

in order to ensure operator exposure to such

hazardous materials is minimized. Applying

conversion coating solution with the Touch-N-

Prep pens helps reduce and eliminate some of the

concerns in regard to operator exposure to

hazardous materials. The operator does not have

to worry about dripping solution, even when

applying conversion coating overhead (See

Figure 3). There are no contaminated cloths,

brushes, or rinse water which can expose the

operator to the chromic acid. The pens are very

efficient at applying the proper amount of

conversion coating solution, which results in

reduced amounts of conversion coating being

used and a minimal amount being wasted.

To aid in the implementation of the Touch-N-

Prep pens and educate the production floor

operators on proper pen usage, Boeing-St. Louis

Environmental Assurance conducted training

classes. As part of the training, an actual

demonstration of how the pen works was given to

the floor operators, as an aluminum test panel

was conversion coated using the Touch-N-Prep

pen. This class provided an excellent opportunity

for the operators to ask questions and express

their concerns about the process and pen. A tip

sheet was also handed out to each operator. This

tip sheet is a training aid that shows the step-by-

step process in which an aluminum surface is to

be cleaned, deoxidized, and conversion coated

with the Alodine 1132 pens. Approximately 1000

production floor operators received this training.

Figure 2 - Applying Alodine 1132 with Touch-N-Prep

Pen to Restore Coating on Repair Area

The feedback and comments of the operators in

regard to the training class are as follows:

“The tip sheets are good and increase operator

awareness…”

“Shelf life of 24 months is great…”

“Elimination of rinsing and wiping is a big

advantage...”

“The Touch-N-Prep pen provides me with more

accuracy because the coating does not run or

drip onto adjacent surfaces…”

The following are some typical questions from

the operators with answers given during the

training classes:

“The color of the coating is not as deep as the

other processes, is this acceptable?”

Color is no indication of how a conversion coat

will perform, a light brown color is acceptable

per PS 13204.

“There are streak/overlap marks on the test

panel, is this cause for rejection?”

Color shades, lines or coating overlap marks are

acceptable per PS 13204.

Figure 3 - Operator Applying Conversion Coating

Overhead with Touch-N-Prep Pen

“Are the Touch-N-Prep pens a replacement for

the other methods, or can we still brush or spray

the alodine material?”

The Touch-N-Prep pens are not a replacement,

but offer an option to apply conversion coat per

PS 13204.

“What is the dry time, how soon can we apply

paint (primer/topcoat) to the Alodine?”

Dry time is usually 5 minutes or less, and paint

coatings can be applied after this time.

“Can we use the Touch-N-Prep pens for

electrical bond applications?”

The Touch-N-Prep pens are approved per MIL-

DTL-81706, Class 3, for protection against

corrosion where low electrical resistance is

required.

“Do we have to apply two coats of conversion

coatings?”

No, two coats are not a requirement, but two

coats are recommended as to provide maximum

corrosion protection.

“What about confined and restrictive areas, how

do we get the felt tip marker in such areas?”

The felt tip on the Touch-N-Prep pen can be

trimmed to fit small areas.

Feedback was also obtained from the floor

operators after one month of using the Touch-N-

Prep pens. Some of the feedback comments are as

follows:

“The Touch-N-Prep pens are great, no rinsing

and wiping and thus no waste to get rid of…”

“The conversion coating does not migrate and

get on surrounding areas; the Touch-N-Prep

pens are easy to use...”

“Using the Touch-N-Prep pen saves me time

and makes my job a lot easier...”

“It’s nice to be able to use the Touch-N-Prep

pens when working overhead, and not worry

about alodine dripping on me…”

“I wish I could use the Touch-N-Prep pen on

titanium, and also on stainless steel…” NOTE:

Alodine 1132 is only allowed to conversion coat

aluminum at this time.

The implementation of the Touch-N-Prep pens

here in St. Louis is proving to be beneficial.

These pens are a good alternative to reduce

chromium exposure and waste. There are some

issues to be addressed, but with the continued

effort and support of Environmental Assurance

and the vendor, Henkel Surface Technologies,

these issues will be resolved.

For additional information or questions concerning

the use of Touch-N-Prep Alodine 1132 pens, contact

George S Giulvezan Jr. at 314-234-6213, or E-mail

[email protected]

or Steve Gaydos at

314-233-3451, or E-mail

[email protected]

States Are Determining New Ozone Non-attainment Areas Now

In December 2002, state governors received

letters from the U.S. Environmental Protection

Agency asking each state to determine those

areas that fail to meet a new, more stringent,

ambient air quality standard for ozone. The new

“8-hour ozone standard” is based on an 8-hour

averaging time. The new 85-part per billion limit

is more difficult to meet than the earlier one hour

standard of 125 ppb. Some areas that achieved

the old standard are not meeting the new

standard. Newly designated non-attainment areas

are likely to face future emission controls on

volatile organic compounds and nitrogen oxides

that were not previously required.

Recent data indicate that 291 U.S. counties have

air quality monitors that exceed the 8-hour ozone

standard. States will not simply declare non-

attainment area boundaries based on monitoring

data, however. EPA guidance directs the states to

consider boundaries based on Metropolitan

Statistical Areas or Consolidated Metropolitan

Statistical Areas (C/SMAs). The C/SMAs are

Census Bureau boundaries that often include

multiple counties in and near urban areas. From

the EPA’s perspective, C/SMA boundaries are

the presumptive non-attainment area boundaries

for the 8-hour ozone standard. States may,

however, propose non-attainment areas larger or

smaller than the C/SMA. If a state believes that

areas outside the C/SMA contribute significantly

to urban ozone levels, or will do so in the future,

the state may create a non-attainment area larger

than the C/SMA. On the other hand, if some

areas of the C/SMA are topographically isolated,

rural, and have low stationary and mobile source

emissions, the state may propose to exclude them

from the non-attainment area.

Future emission control requirements will be

more stringent within the non-attainment area

than outside it. As a result, non-attainment

boundary decisions generate great concern and

interest and by state and local officials,

environmental advocates, industrial and military

facilities, and exurban commuters who may face

new vehicle inspection requirements, clean fuel

costs, etc. Many states are now engaged in

stakeholder meetings or public hearings to

determine what the boundaries will be. State and

local non-attainment designations are due to the

EPA in April 2003. EPA will review the

proposed designations, seek public comment, and

approve or disapprove them by April 2004. In

the meantime, EPA will complete rulemaking to

determine what emission control strategies will

be required for 8-hour non-attainment areas. SIPs

(State Implementation Plans) for achieving the 8-

hour ozone standard will be due to EPA around

2007, though many states are already engaging

the industrial community and citizens in efforts to

achieve earlier emission reductions.

For additional information, contact Dave Shanks at

314-234- 4351, or E-mail [email protected]

Your comments are Important to us! Contact Paul Rempes at (314) 233-1541 or e-mail: [email protected]

Archived issues are located on the Boeing Intranet at: http://engmil.stl.mo.boeing.com/engmil/ea/

For questions regarding access, call Craig Scott at (314) 234-1736, e-mail: craig.w.scot[email protected]