IVD of Aluminum
DEPOT MAINTENANCE PROJECT as of 940923
Type: E/T
Accession Number: 11800
Code: Active
Narrative:
The IVD aluminum process is an alternative for replacing cadmium and nickel-cadmium electroplating on 80% of parts cadmium plated at McClellan AFB. This technology offers decreased environmental contamination, improved plating performance over cadmium based systems.
Funding: $660K
Application/Source: Electroplating
Pollutant Category: Heavy Metals, Cyanides, Acids
Governing Regs/Laws: 40 CFR 265, aa CAC CH 30; Mil Specs: MIL-C-83488C, MIL-C-5541, MIL-S-5002, MIL-T-9046, MIL-S-18729
Status: Nov 89 Contract awarded.
Implementation Date: 1991
Initial Submission Date: 1988-01-01
Update Submission Date: 1991-04-30
Lead Service: Air Force
Key Words: Cadmium Plating, Electroplating, Ion Vapor Deposition,
Point of Contact – Name: Torres, B.
Point of Contact – Organization: SM-ALC/TIME
Point of Contact – Phone: AV 633-2704/Comm (916) 643-2704
Comments: Three tests are required IAW MIL-C-83488; (1) thickness test; (2) adhesion test, and (3) salt spray test. The following parts have been ivadized: F-15 ribs, F-111 horizontal stabilizer intercostals and outboard bearing housing, “L” cylinder, B-52 piston. Thickness and adhesion tests performed with desired results on the following parts: F-15 ribs, F-111 horizontal stabilizer intercostals and outboard bearing housing, “L” cylinder and B-52 pistons. Still undergoing salt spray test for the above parts. Salt spray testing passed on corrosion panel for calibrating chamber. (No production part in relation to corrosion panel.
Plating – IVD
DEPOT MAINTENANCE PROJECT as of 940923
Type: E/T
Accession Number: 37927
Code: Cancelled
Narrative:
Ion Vapor Deposition is a process by which aluminum is vaporized and adheres to parts. The process requires strict controls, a vacuum, proper air conditioning, dehumidifying, and avoidance of contaminates.
Funding: $900K, (FY91)
Application/Source: Substitution for cadmium plating
Pollutant Category: Heavy metals
Governing Regs/Laws: CWA, RCRA
Status:
- Contract through NADEP Norfolk (# N00189-91-R-0123) to be awarded 10-01-91.
- Aug 93 This project will be tracked through accession number 41376
Initial Submission Date: 1991-07-29
Update Submission Date: 1993-08-12
Lead Service: Army
Key Words: Ion, Vapor, Vacuum
Point of Contact – Name: Holiday, James
Point of Contact – Organization: Corpus Christi AD
Point of Contact – Phone: DSN 861-3243/3979
IVD
DEPOT MAINTENANCE PROJCET as of 940923
Type: E
Accession Number: 8973
Code: Completed
Narrative:
Cadmium is the major contaminant and in some cases the only reason for a waste being classified as a hazardous waste. Reduction in the amount of cadmium being used will help minimize HW. Unit installed for IVD of aluminum vice use of cadmium coatings where possible.
Funding: $350,000
Application/Source: All Wastes Contaminated with Cadmium
Pollutant Category: Solid Waste
Governing Regs/Laws: RCRA
Status:
- Jul87 Unit Currently in Production, New Applications Being Added as Identified.
- Apr94 75% of the cadmium plating workload formerly performed in our plating facility is now accomplished by IVD. This has significantly reduced the cadmium wastestream from the plating facility.
Initial Submission Date: 1987-07-01
Update Submission Date: 1994-04-29
Lead Service: Navy
Key Words: Cadmium, Ivadize, Ion Vapor Deposition, IVD, Minimize
Point of Contact – Name: Whitt, Kevin
Point of Contact – Organization: NADEP Norfolk, CODE 611
Point of Contact – Phone: AV 564-8398/Comm (804)444-8398
DEPOT MAINTENANCE PROJECT as of 940923
Type: E
Accession Number: 8989
Code: Completed
Narrative:
This project will replace nickel-cadmium (Ni-Cd) plating with a nontoxic substitute, IVD of aluminum. Alternatives considered/reasons deleted : Continued use of nickel cadmium plating/continued worker exposed to toxic substances, high disposal costs, failure to reduce waste generation. Benefits: Elimination of the following waste streams associated with Ni-Cd plating: plating solutions, contaminated rinsewaters, blast waste. Less worker exposure to hazardous substances. Compliance with the federal requirement for implementation of a waste minimization program. Impact if not provided: Failure to achieve waste minimization goal.
Funding: Cost: $337,000; Anticipated Fund Source:
Pollutant Category: Electroplating Solutions and Rinsewaters, Blast Media
Status:
- 1988 Purchased and installed the IVD equipment. Process has proven to be an acceptable alternative for both nickel-cadmium and cadmium plating.
- The program has had limited success. Approximately 33% of the previous workload has been shifted to the alternative process of IVD. Better management of the process has significantly reduced the amount of Ni-Cad waste generated. Final report is a Tyndale AFB Study.
Implementation Date: October 1988
Initial Submission Date: 1988-11-03
Lead Service: Air Force
Key Words: Ion Vapor Deposition, Ivadize, IVD, Plating
Point of Contact – Name: Nancy Stapper
Point of Contact – Organization: SA-ALC/LLP
Point of Contact – Phone: DSN 945-5338
Lessons Learned: Threaded components for Kelly’s workload are not being processed through the IVD process as yet because torque tension values need to be determined for the aluminum coatings applied. Warner-Robbins is processing their threaded components and using a lubricant upon installation to compensate for differences in torque tension values. Have experienced a series of equipment problems resulting in increasing amounts of downtime.
DEPOT MAINTENANCE PROJECT as of 940923
Type: E
Accession Number: 8994
Code: Completed
Narrative:
The ION Vapor Deposition system will replace cadmium electroplating with IVD of aluminum. Alternatives considered/reasons deleted: Continue to cadmium plate – this has the continuing disadvantage of cadmium waste generation, potential for worker exposure to toxic material and difficulties treating cadmium at the IWTP. Benefits: Superior corrosion protection. Will reduce the generation of cadmium contaminated waste from the plating and blasting processes minimizing waste treatment and disposal cost and potential worker exposure. Impact if not provided: F-15 workloads will continue to be contracted out. Toxic cadmium waste (rinsewater and blast media) will continue to be generated unabated.
Anticipated Funding Source: DERA
Equipment Cost: $448,648;
Pollutant Category: Electroplating/Solutions, Rinsewater
Status:
- Project underway at Robins in cooperation with Air Force Engineering Services Center at Tyndall and McDonnell to adapt all workload to IVD (i.e. solve internal diameter problems where possible, qualify IVD for use on fasterers etc). 85% of Robins workload has currently been validated for IVD. It is anticipated that IVD will be approved for the remaining 15% by end of Calendar 1991.
- Jan 93 Project is completed. All cadmium electroplating workload has been converted to IVD. No major problems were encountered except for tech order changes.
Implementation Date: 1990
Initial Submission Date: 1988-11-03
Update Submission Date: 1993-01-14
Lead Service: Air Force
Key Words: Aluminum, Cadmium, Corrosion, Ion Vapor Desposition, IVD
Point of Contact – Name: Walker, Marti
Point of Contact – Organization: WR-ALC/TIBO
Point of Contact – Phone: AV 468-4800
