Lead-Free Dry Film Lubricants
(Propulsion Environmental Working Group)
Project Number: S-95-SP-007

Meeting and Teleconference Summaries

Potential Programs/Owners: F100, F101, F103, F107, F108, F110, F112, F117, F118, F119, F404, F414, J52, LM1600, LM2500, LM6000, T53, T55, T56, T64, T406, T700, T800, TF30, TF33, TF34, TF39, TF40 engines

Material(s) Targeted for Reduction/Elimination: Lead as DFLs

Phase(s) in Methodology: III, Business and IV, Demonstration/Validation

Milestones and Prior Decisions:

• Lead in DFLs was selected as the target HazMat.
• The preliminary screening criteria for candidate alternative DFLs were specified.
• The tests required to validate the alternatives were defined.
• An initial set of candidate nonlead DFLs were selected for testing.
• Initial testing of selected candidate nonlead DFLs in late summer of 1998.
• Some candidate alternative DFLs have been eliminated from testing, leaving three DFLs currently in testing.
• Torque tension testing of Everlube 10030 has been halted due to poor test results at 950°F and 1100°F.
• Stakeholders agreed to accept Pratt & Whitney's torque tension test data to qualify Tiolube 614-T9B as a lead-free DFL for antiseize applications.
• Humidity resistance was identified as an additional qualification test requirement for antigalling DLFs.

Summary:

On June 2, 2003, technical stakeholders met during the PEWG meeting in New Orleans, LA, to discuss the status and issues associated with the JG-PP/PEWG Lead-Free DFL task. The breakout technical working group meeting provided a forum for CTC, DoD stakeholders, and OEM representatives to discuss the technical approach, status, issues, and future activities. Eight action items were assigned.

On July 22, 2002, technical stakeholders met during the semi-annual PEWG meeting in Cincinnati, OH, to discuss the status and issues associated with the Non-Lead DFL task. The breakout technical working group (TWG) meeting provided a forum for CTC to obtain feedback on a variety of technical issues associated with torque tension testing and sliding wear testing of Everlube 812, Everlube 10030, and Tiolube 614-T9B. It also provided government and OEM representatives the opportunity to voice their requirements and concerns.

On February 4, 2002, technical stakeholders met during the semi-annual PEWG meeting in San Diego, CA, to discuss the status and issues associated with the Non-Lead DFL task. The breakout technical working group (TWG) meeting provided a forum for CTC to obtain feedback on a variety of technical issues associated with torque tension testing and sliding wear testing of Everlube 812, Everlube 10030, Tiolube 614-T9B, and Tiolube 614-T8E. It also provided government and OEM representatives the opportunity to voice their requirements and concerns.

On July 9, 2001, as part of the Summer PEWG 2001 meeting, a technical working group meeting was held to discuss technical issues pertaining to the JG-PP/PEWG Non-Lead DFL project. The project coordinators from CTC met with project stakeholders from the PEWG, OC-ALC, NAVAIR, AMCOM, AIEC, P&W-UTC, and GEAE.

On February 5, 2001, Heather Moyer presented a status update on the Lead-Free DFL task at the Winter PEWG meeting.

On March 21, 2000, representatives from P&W-UTC, NDCEE/CTC, and the PEWG participated in a teleconference to discuss whether or not to include Everlubeâ 812 in Phase IV of DFL testing. The participants in this teleconference agreed that including Everlube 812 in Phase IV testing is a good idea. The draft JTR containing the results of testing Phases I through III will be modified to include the rationale for including Everlube 812 in Phase IV testing even though it failed the Sulfurous Acid Salt Spray test (JTP section 3.13), and distributed to project participants for their concurrence.

On May 19, 1999, representatives from AFMC, AMCOM, AIEC, NAWCAD, OC-ALC, Pacific Environmental Services, P&W - UTC, Rolls-Royce Allison, the JASPPA, and the PEWG met to discuss the progress of DFL testing. No open action items were closed, and eight new action items were assigned. These action items are intended to facilitate further testing of DFLs. E/Mâ 1380B, Surf-Koteâ LOB-1800G, and Tiolube 614-T9B will be subjected to Phase II tests. Everlubeâ 10030 may replace E/M 1380B in further testing, depending on the response to one action item. Surfaces Research SRA #1 will be tested in Phase I if Surfaces Research returns coated test panels by June 18, 1999. Everlube 812 will be tested in Phase III when other DFLs have been selected for simultaneous Phase III testing.

On May 12, 1998, representatives from AlliedSignal Engines and the PEWG met to discuss the DFL testing requirements specific to engines manufactured by AlliedSignal Engines. DFLs and test requirements specific to those engines manufactured by AlliedSignal Engines were identified. No open action items were closed, and no new action items were assigned.

On April 6, 1998, representatives from GEAE, the DCMC, the PEWG, and the JPPAB participated in a meeting to discuss candidate alternative DFLs and GEAE-specific testing. No open action items were closed. DFLs and test requirements specific to the GEAE engines were identified. Participants in this meeting are to investigate the suitability of paste lubricants for the intended use, identify Navy defense systems using the GEAE LM2500 engine, and provide details about test substrates and acceptance criteria specific to the GEAE engines.

On August 14 and 15, 1997, representatives from AlliedSignal Engines, Allison Engine Company, GEAE, Williams International, F404/F414, F100, OC-ALC, ASC/EM, the NAWCAD, the DCMC, the PEWG, and the JPPAB participated in a meeting to discuss the JTP, candidate alternative DFLs, testing strategy, and business issues. Open action items J/P.97.04.01, J/P.97.04.02, J/P.97.04.03, J/P.97.04.06, J/P.97.04.10, J/P.97.04.11, J/P.97.05.01, J/P.97.05.04, and J/P.97.07.01 were closed. Final changes were made to the JTP, and thirteen (13) candidate alternatives were selected to be tested. The participants redefined the four test sets to be performed sequentially. The first test set will be performed on the thirteen alternatives listed above, at which time the technical representatives will discuss the test results and select DFLs to be tested further.

On July 15, 1997, technical representatives from AlliedSignal Engines, Allison Engine Company, GEAE, P&W-UTC, F404/F414, F100, OC-ALC, U.S. Army Mobility Technology Center (Fuels & Lubes Lab), the DCMC, and the JPPAB participated in a teleconference to discuss the draft JTP dated 10 Jun 97 and to make further decisions on the preliminary screening criteria used to reduce the number of candidate alternatives being considered. The group agreed to modify the Reciprocating Sliding Wear test (Section 3.9 in the 10 Jun 97 draft JTP) to allow the use of either described specimen configuration for galling and fretting. The group also discussed the possibility of modifying the test to eliminate the intermediate visual inspection of specimens. All participating organizations except P&W - UTC agreed to this change; P&W - UTC will provide a decision within two weeks (AI J/P.97.07.01). The technical representatives decided to exclude DFLs containing graphite from consideration for the assembly aid application category. DFLs provided in paste form or containing antimony trioxide will also be excluded. DFLs containing ethyl alcohol or quartz will be considered further, even though those compounds are carcinogens. The participants further decided that DFLs will be excluded from further consideration if they can only be applied by the DFL manufacturer, with no possibility of licensing the process for use in an OEM facility. Action items J/P.97.04.09, J/P.97.04.15, J/P.97.04.16, J/P.97.05.02, and J/P.97.05.03 were closed.

On May 27, 1997, TRs from AlliedSignal Engines, Allison Engine Company, P&W-UTC, ASC/EME, NAWCAD, ATCOM, the PEWG, the DCMC, and the JPPAB participated in a teleconference to discuss the approach to testing of candidate alternatives to existing lead-containing DFLs. Action items J/P.97.04.04, J/P.97.04.05, J/P.97.04.07, J/P.97.04.08, J/P.97.04.12, J/P.97.04.13, and J/P.97.04.14 were closed. The group decided to execute the JTP testing in four sequential sets of tests, with decisions about the acceptability of candidate alternative DFLs made by group consensus after completion of each test set. The first test set will include a Dry Tape Adhesion test, which will be added to the draft JTP. Action items were assigned to recommend whether or not graphite should be allowed as an ingredient of candidate alternative DFLs, formulate suggested wording to incorporate management consulting into the testing cost estimates, and to provide contacts at the OEMs to receive a letter seeking reinforcement of corporate support for the DFL project.

On May 8, 97, Technical representatives from AlliedSignal Engines, Allison Engine Company, P&W-UTC, ASC/EME, NAWCAD, ATCOM, PEWG, and the JPPAB participated in a teleconference to discuss the JG-APP/PEWG Joint Pilot Project for eliminating lead as found in DFLs. The identified candidate alternatives were discussed, along with the criteria that will be used to reduce the number of alternatives being considered, based on available information. Some of the criteria that were chosen were that candidate DFLs should contain no chromium, cadmium, methylene chloride, butyl cellosolve, methyl ethyl ketone, perc solvents, or carcinogens, and that lead content should be below 100 ppm. In addition, it was decided that candidate DFLs will be eliminated from consideration if their VOC content is above 500 g/L.

On April 29 and 30, 1997, Technical Representatives from AlliedSignal Engines, Allison Engine Company, GEAE, P&W-UTC, NADEP - Jacksonville, ASC/EME, NAWCAD, USA ATCOM, DCMC, PEWG, and JPPAB met at AlliedSignal Engines, Phoenix, AZ, to discuss the JG-APP/PEWG Joint Pilot Project for eliminating lead as found in DFLs. The draft JTP dated 22 Apr 97 was discussed. The group agreed to a number of modifications to the tests, including reductions in the number of different substrate materials used for the Reciprocating Sliding Wear test (Sections 3.8) and the Torque-Tension Evaluation (Section 3.16). These reductions will significantly reduce testing costs per alternative. All changes made to the 22 Apr 97 draft JTP as a result of the meeting are documented in the minutes. The participants also discussed a test cost matrix showing the most economical testing facility for each test required based upon an earlier (7 Mar 97) draft JTP. The participants agreed that each potential test facility will be asked to submit revised engineering cost estimates to conduct JTP testing based upon the updated JTP. The group discussed a previous statement by a Williams International representative that lead-containing DFLs had been eliminated from their processes; an action item was assigned to determine the validity of this statement. Mr. Robert Hill, JPPAB, led the group through a discussion of possible cost adjudication methods, and advised the participants about an opportunity to have cost validation studies for the DFL initiative performed under the ESTCP.

On January 23 and 24, 1997, Technical Representatives from AlliedSignal Engines, Allison Engine Company, GEAE, P&W-UTC, Fuels & Lubes Lab, NADEP-Jacksonville, ASC/EME, NAWCAD, the DCMC, the PEWG, and the JPPAB met at P&W-UTC, West Palm Beach, FL, to discuss the draft (dated 15 Jan 97) JTP for the JG-APP/PEWG Joint Pilot Project for eliminating lead as found in DFLs. All of the test descriptions in the JTP were discussed. Consensus was used to assure that the group was in agreement. All required changes to the JTP as a result of the meeting are documented in the minutes.

On January 13, 1997, TRs from AlliedSignal Engines, Allison Engine Company, GEAE, P&W-UTC, NASA, OC-ALC, Fuels & Lubes Lab, ASC/EME, the PEWG, and the JPPAB participated in a teleconference to discuss the draft (dated 1 Nov 96) JTP for the JG-APP/PEWG Joint Pilot Project. The group discussed the tests described in Sections 3.21.1 and 3.21.2 of the draft JTP. The participants agreed to remove the Falex Block-on-Ring Friction and Wear test of Section 3.21.1 from the draft JTP. Modifications were made to the Reciprocating Sliding Wear test of Section 3.21.2, but further discussion of this test will be required at the next meeting.

On December 13, 1996, Technical Representatives from AlliedSignal Engines, Allison Engine Company, P&W-UTC, the PEWG, and the JPPAB participated in a teleconference to discuss the draft (dated 1 Nov 96) JTP for the JG-APP/PEWG Joint Pilot Project. The group discussed the tests described in Sections 3.20 and 3.21 of the draft JTP. The participants agreed to move the VOC Analysis test of JTP Section 3.20 to Implementation and Quality Control Tests (JTP Section 4). Action items were assigned for comments and suggestions on the Wear Resistance and Coefficient of Friction tests of JTP Section 3.21. The group planned to discuss these tests further during a 13 Jan 97 teleconference.

On Dec 6, 1996, Technical Representatives from Allison Engine Company, GEAE, P&W-UTC, and the JPPAB participated in a teleconference to discuss the draft (dated 1 Nov 96) JTP for the JG-APP/PEWG Joint Pilot Project. The group discussed a proposed combination of the tests described in Sections 3.2, 3.7, 3.10, and 3.19. The draft written test description distributed before the teleconference required further detail; P&W-UTC took responsibility to provide an updated test description for inclusion in the next update of the draft JTP.

On November 22, 1996, Technical Representatives from Allison Engine Company, GEAE, P&W-UTC, Williams International, NAWCAD, the PEWG, and the JPPAB participated in a teleconference to discuss the draft (dated 1 Nov 96) JTP for the JG-APP/PEWG Joint Pilot Project. The group discussed the tests described in Sections 3.16 through 3.18 of the draft JTP. The decisions made by the participants about these tests (Surface Condition, Thermal Shock Stability, and Thermal Stability by Simultaneous Differential Thermal Analysis - Thermogravimetric Analysis) will be incorporated into the next update of the draft JTP. These decisions included definition of application categories for each test and determination of appropriate test conditions. Substrate materials were discussed for the Thermal Shock Stability test, but the participants agreed to postpone decision until the 23 and 24 Jan 97 technical meeting.

On November 7, 1996, Technical Representatives from Allison Engine Company, GEAE, P&W-UTC, Williams International, NAWCAD, the PEWG, and the JPPAB met at GEAE, Evendale, OH, to discuss the progress on the JTP for the JG-APP/PEWG Joint Pilot Project. The group discussed approximately three-quarters of the tests contained in the draft JTP and scheduled a series of teleconferences to discuss the remaining tests.

This site last updated February 28, 2008.