This article is based on an official press release from Marshall Aerospace.

The Silver Skin: Inside the Critical C-130 Paint Stripping Process

For military aviation enthusiasts and industry observers, the C-130 Hercules is most recognizable in its operational livery, typically grey, camouflage, or specific squadron markings. However, before these workhorses undergo major maintenance, they must be stripped down to their raw, metallic core. According to Marshall Aerospace, this transformation is not merely aesthetic but a critical safety requirement for ensuring the airworthiness of global fleets.

In a recent release titled “What lies beneath,” Marshall Aerospace detailed the rigorous process of chemically stripping C-130 Military-Aircraft to bare metal. This procedure, often hidden behind closed hangar doors due to safety protocols, is the first step in a “deep tissue” examination of the airframe. By removing layers of paint and primer, maintenance crews can expose the aircraft’s “silver skin,” revealing microscopic defects that would otherwise remain invisible to the naked eye.

As a “Gold Standard” partner for Lockheed Martin, Marshall Aerospace performs this essential work at its facility in Cambridge, UK. The company notes that this capability is vital for Planned Maintenance Intervals (PMI), a heavy maintenance check that occurs roughly every five to six years. Without this complete strip, engineers cannot guarantee the structural integrity required for the demanding operational profiles of clients like the US Marine Corps.

The Transformation: From Paint to Bare Metal

The process of stripping a C-130 is an intense industrial undertaking that typically occurs within the first 10 days of the aircraft’s arrival for maintenance. Marshall Aerospace describes the procedure as a complete “transformation” that takes place in a dedicated “paint barn” large enough to house a Boeing 747.

Chemical Stripping and Containment

Unlike minor inspections where paint remains intact, major maintenance events require the removal of all coatings. Marshall Aerospace utilizes a specialized chemical stripping process to achieve this. Before the chemicals are applied, technicians meticulously mask sensitive areas of the aircraft. Windows, composite parts, and radomes are covered with aluminum tape and protective materials to prevent chemical intrusion, which could damage these delicate components.

Once prepared, the aircraft is treated with a chemical agent designed to loosen the bond between the paint, primer, and the metal skin. The coating is then washed away, leaving the aluminum alloy structure exposed. Because the process involves harsh chemicals and heavy metals from the old paint, Marshall emphasizes the use of advanced environmental abatement systems. These systems capture hazardous waste and filter the air, ensuring that pollutants do not escape into the atmosphere or local water supply.

Safety Protocols

The environment inside the paint barn is strictly controlled. Technicians working on the strip must wear full Personal Protective Equipment (PPE), including respirators and protective suits. This level of protection is necessary to handle the stripping agents safely while preparing the aircraft for the next stage of its maintenance journey.

Why the Strip is Non-Negotiable

While a freshly painted aircraft looks impressive, Marshall Aerospace asserts that the true value of maintenance lies in what is uncovered when the paint is removed. The “silver” state of the aircraft allows for a level of inspection that is impossible to achieve on a painted airframe.

Detecting Hidden Defects

Paint can effectively hide stress cracks, corrosion, loose rivets, and fatigue issues. By stripping the aircraft to bare metal, engineers can perform rigorous Non-Destructive Testing (NDT) and visual inspections on every inch of the skin. This “detective work” is crucial for identifying structural weaknesses that could compromise the aircraft’s safety during flight.

“We understand that there is more to aircraft paint than the appearance… looking at what is under the surface is key to our maintenance inspections.”

, Marshall Aerospace Technical Materials

Weight and Balance

Beyond inspection, the stripping process plays a role in aircraft performance. Over time, multiple layers of paint can add significant weight to an airframe. Stripping and repainting help maintain the aircraft’s correct weight and center of gravity, ensuring it performs within its design specifications.

AirPro News Analysis

The emphasis on deep-level maintenance capabilities like paint stripping highlights a broader trend in the aerospace defense sector: the extension of airframe life. With the C-130 platform remaining a backbone of global military logistics, the ability to detect and repair fatigue in aging airframes is becoming as valuable as the production of new units. Marshall Aerospace’s expansion into the United States, with a new facility in Greensboro, North Carolina, suggests a growing demand for these heavy MRO capabilities on both sides of the Atlantic.

Marshall’s Legacy and Future

Marshall Aerospace has established itself as a global authority on the C-130 platform. The company has been working on the Hercules since 1966 and became the first authorized C-130 Hercules Service Centre (HSC) in the world in 1974. In February 2025, the company celebrated 50 years holding this designation.

The company services major international fleets, including the US Marine Corps and the Royal Air Force. With the upcoming facility in Greensboro, Marshall is set to expand its “paint barn” capabilities, bringing its specialized stripping and maintenance processes closer to its North-American customer base.

Frequently Asked Questions

Why is paint stripping necessary for C-130 maintenance?

Stripping paint is required for Planned Maintenance Intervals (PMI) to expose the bare metal skin. This allows engineers to detect hidden cracks, corrosion, and fatigue that paint might conceal.

How long does the stripping process take?

According to Marshall Aerospace, the stripping process is typically completed within the first 10 days of the aircraft’s arrival for major maintenance.

Where does Marshall Aerospace perform this work?

Currently, the work is performed at their facility in Cambridge, UK. A new facility with similar capabilities is opening in Greensboro, North Carolina.

Sources

• Marshall Aerospace

This article summarizes reporting by BBC News and official statements from the Peruvian Air Force.

Tragedy Strikes Arequipa: 15 Dead in Military Helicopter Crash

Fifteen people have died following the crash of a Peruvian Air Force (FAP) Helicopters in the southern Arequipa region, authorities confirmed on Monday. The Mi-17 aircraft, which was deployed to assist with humanitarian relief during severe flooding, lost radio contact on Sunday afternoon before being located the following morning.

According to reporting by BBC News, the wreckage was discovered in the Chala district. Officials stated that there were no survivors among the 15 occupants, a group that included four crew members and 11 passengers. The tragedy has compounded the devastation in a region already grappling with torrential rains, landslides, and overflowing rivers.

The Peruvian Air-Forces confirmed the loss in an official statement, noting that the aircraft was executing a support mission between the city of Pisco and Chala. The incident highlights the extreme risks facing emergency responders as they navigate the treacherous weather conditions currently battering southern Peru.

Flight Details and Recovery

The Russian-made Mi-17 transport helicopter departed Pisco in the Ica region on Sunday, February 22, 2026, intending to reach Chala in Arequipa. Radio contact was lost at approximately 4:30 PM local time. Search and rescue teams, including Special Forces patrols, located the crash site near Chala Viejo on Monday morning, February 23.

Local media reports indicate that the flight was intended to bypass road blockages on the Pan-American Highway caused by landslides. The passenger list included military personnel and civilians, some of whom were reportedly relatives of the armed forces members on board.

Casualty Breakdown

Authorities have identified all 15 victims. The four crew members were identified as Major Sergio Danner Paucar Centurión (pilot), Second Lieutenant Luis Fernando Huertas Cárcamo, and Technicians Kamila Chapi Anchapuri Jove and Leiner Aguirre Huamán.

Among the 11 passengers, the loss of life included seven children ranging in age from 3 to 17 years old. Three civilian women and one military officer, Colonel Javier Nole Gonzales, were also killed. In a statement regarding the victims, the Air Force expressed its grief:

“Our deepest condolences to the family members, friends, and the entire FAP family for the irreparable loss of our crew and passengers.”

, Peruvian Air Force (FAP) statement

Severe Flooding Crisis in Arequipa

The crash occurred against the backdrop of a severe environmental emergency. The Arequipa region has been inundated by torrential rains that have triggered huaicos (mudslides) and caused rivers to breach their banks. According to local authorities, the Chullo ravine overflowed, sending mud and debris through residential streets.

Beyond the helicopter crash, the storm system has claimed at least two other lives. Local media reported that an elderly woman was swept away by floodwaters in the Cayma district, and a man was struck by lightning in Uchumayo. Infrastructure damage is widespread, with estimates suggesting hundreds of homes have been affected, some rendered uninhabitable by mud ingress up to a meter high.

Regional Governor Rohel Sánchez has requested urgent assistance from the national government, citing that local response capabilities have been overwhelmed by the scale of the disaster.

AirPro News analysis

Operational Risks in Andean Relief Missions The loss of the Mi-17 highlights the persistent dangers of conducting aerial operations in the Andean region during the rainy season. The Mi-17 is a workhorse of Latin American military aviation, prized for its high-altitude performance and ruggedness. However, the combination of mountainous terrain and rapidly changing microclimates, common during “huaico” season, creates a perilous operating environment even for experienced crews.

While the Investigation is ongoing, this incident underscores the heavy reliance on military airlift when ground infrastructure fails. With the Pan-American Highway blocked, air transport becomes the only lifeline, forcing aircraft to fly sorties in marginal weather windows. This tragedy may prompt a review of civilian transport protocols on military aircraft during active emergency declarations.

Frequently Asked Questions

What caused the crash? An official investigation has been launched by the Peruvian Air Force’s Accident Investigation Board. No specific cause, such as mechanical failure or pilot error, has been determined yet, though the crash occurred during severe weather conditions.

Who were the civilians on board? The civilians included three women and seven children. Local media reports suggest they were relatives of military personnel being transported to avoid road blockages caused by the floods.

What is the status of the flooding in Arequipa? The region remains in a state of emergency. Heavy rains have caused landslides and flooding, damaging hundreds of homes and claiming lives independent of the aviation Accident.

Sources

• BBC News
• Andina (Peru News Agency)
• Peruvian Air Force (FAP)

This article is based on an official press release from Kratos Defense and additional industry reporting.

Kratos and GE Aerospace Secure Air Force Contract for New GEK1500 Engine

Kratos Defense & Security Solutions and GE Aerospace have been awarded a $12.4 million contracts by the U.S. Air Force to develop a new engine tailored for the next generation of unmanned aerial systems. The award funds the preliminary design of the GEK1500, a 1,500-pound thrust class turbofan engine intended to power “expendable” Collaborative Combat Aircraft (CCA).

According to the official announcement from Kratos, this development effort aims to support the Air Force’s strategic goal of “affordable mass”, deploying large numbers of low-cost autonomous drones to overwhelm adversary defenses. The GEK1500 is specifically designed to bridge the gap between short-range munitions and long-endurance aircraft, offering a cost-effective solution for systems that may not be expected to return from every mission.

Designing for “Limited Life” Operations

The GEK1500 represents a departure from traditional fighter engine design, which prioritizes durability over thousands of flight hours. Instead, this new engine is engineered for “limited life” applications. This design philosophy allows for significant cost reductions while maintaining the performance necessary for relevant combat ranges.

In a press statement, Steve Russell, Vice President of Combat Capability Systems at GE Aerospace, highlighted the engine’s developmental lineage:

“Lessons learned from recent GEK800 altitude testing are directly informing GEK1500… so we can meet CCA requirements without compromising affordability or schedule.”

The engine scales up the architecture of the smaller GEK800, an 800-pound thrust engine originally developed for cruise missiles. By leveraging this existing technology, the joint team aims to accelerate development timelines and mitigate technical risks.

Turbofan vs. Turbojet

A critical technical distinction of the GEK1500 is its turbofan architecture. While many existing small expendable systems utilize simpler turbojet engines, the Air Force requires greater fuel efficiency to extend the range of its CCA fleet.

According to reporting by Breaking Defense, GE Aerospace executive Craig Young noted that while turbojets are inexpensive, they lack the fuel efficiency required for the extended ranges demanded by modern combat scenarios.

Strategic Context: The “Expendable” Niche

The U.S. Air-Forces’s CCA program is generally divided into two categories: “attritable” systems, which are high-performance drones designed to return and fly again (such as those being developed by Anduril and General Atomics), and “expendable” systems, which are lower-cost assets designed for high-risk missions or one-way trips.

The GEK1500 targets the latter category. By focusing on the 1,500-pound thrust class, Kratos and GE are positioning this engine to power smaller drones, decoys, and next-generation cruise missiles. This sector of the market requires engines that are sophisticated enough to provide range and speed but cheap enough to be manufactured in high volumes.

AirPro News Analysis

We observe that this contract award signals a potential vertical integration shift for Kratos. Currently, Kratos platforms like the XQ-58A Valkyrie utilize commercial engines from third-party suppliers such as Williams International. By co-developing the GEK1500, Kratos is moving to secure its own supply chain for propulsion.

This move addresses a critical bottleneck in drone production: the availability of small, high-performance engines. If Kratos and GE can successfully mass-produce the GEK1500, they could dominate the propulsion market for the “low-end” CCA segment, distinct from the larger engines required for the Air Force’s Increment 1 “loyal wingman” drones.

Competitive Landscape

The development of the GEK1500 places Kratos and GE Aerospace in direct competition with other major industry players vying to power the Air Force’s future fleet. The 500 to 2,000-pound thrust class has become a hotbed of innovation.

• Manufacturers: Is currently developing the HON1600, leveraging its extensive background in auxiliary power units.
• Pratt & Whitney: Is working on a family of small engines ranging from 500 to 1,800 pounds of thrust.
• Williams International: Remains the incumbent leader, with its engines currently powering the XQ-58A Valkyrie and other prominent systems.

The Air Force has made it clear that it prioritizes high-performing, low-cost engines to enable disruptive capabilities. As the CCA program evolves, the ability to produce these engines at scale will likely determine which manufacturers secure long-term production contracts.

Sources:
Kratos Defense Press Release