Office of Naval Research

Corrosion Control S&T Program

Airan J. PerezUndersea Weapons and Naval Materials Division

Office of Naval Research703-696-0845

pereza@onr.navy.mil

DoD Maintenance SymposiumOctober, 2006

Outline

• Impact of Corrosion on the Navy and Marine Corps

• ONR Program in Corrosion Prevention and Control- Current Research Efforts

• Summary

Naval Operating EnvironmentSea water and Humid Atmosphere laden with

Airborne SaltNOX and SOX

Condensation of Salt WaterWet/Dry Cycle

High Temp. Oxidation, Hot corrosion

Molten Salt , Sulfidation

Amphibious Operations Deployment Abroad

Seawater Fording Splash & Spray

Marine Atmosphere

Problems with Corrosion

• Treatment often inadequate

Significant maintenance required!

• Materials vulnerable

• Inspection not always revealing

Classic Response to Naval Corrosion

….Chip ScrapePaint

Wash…

Impact of Corrosion on the Navy

Corrosion: Navy’s No. 1 Maintenance Problem

$4.44B/Yr

Ships*$2.44B

Aircraft$0.9B

Ground Vehicles& Others $1.1B

Landing Gear – Stress Corrosion Cracks

Fasteners – Exfoliation

Ship TankHMMWV Suspension and Frame

Koch, G. H., Brongers, M. P. H., Thompson, N. G., Virmani, Y. P. and Payer, J. H., Corrosion Cost and Preventive Strategies in the United States, FHWA-RD-01-156, Federal Highway Administration, U.S. Department of Transportation, Washington D.C., 773 pp., March 2002

*The Annual Cost of Corrosion for Army Ground Vehicles and Navy Ships, LMI Report, Apr., 2006

Some Solutions to these Problems

• Better materials• Better coatings• Better inspection/detection methods• Better treatment methods and

technologies

Bottom line: Up front prevention leverages

downstream savings

Science & Technology

Enterprise & Platform Enabler Future Naval Capability (EPE FNC)

• ObjectiveReduce the cost of maintenance due to corrosion and increase readiness as a result

• ApproachDevelop, demonstrate and transition corrosion control, monitoring, prevention and inspection technologies for ships, aircraft, vehicles and facilities

• TechnologiesCoatings, Corrosion-Resistant Materials, Corrosion Preventative Compounds, Sensors, Non-Destructive Inspection Techniques

PL: Corrosion Control Technology

EC: Reduce Support Costs

Single Ship Tank Coatings

Product Description:

Rapid Cure Single Coating SystemsFor Enhanced Corrosion Control• Solvent free• Edge retentive• One high build

Before (Aug 02)

After (Mar 03)

Payoff:

USS WHIDBEY ISLAND LSD-41Seawater Ballast Tank 3-129-1-W

Application of Ultra Polyurethane

• Life cycle savings: $250M• Quick return to service• Can be applied in hot and cold weather• Waterborne (pier-side) application

capability• Long life and durability (>current

systems)

Modular Hybrid Pier

Product Description: Proof of Concept in Modular, Floating,Double-Deck Pier Constructed ofCorrosion Resistant Materials

Payoff:• Life cycle savings $460M• 100 years service life• 80% reduction in maintenance and

repair

General Purpose Berthing Pier – Surface Combatants & Amphibs

Demonstration of towable modules built with new design and durable materials

site

Tacoma, WA

Concrete Technology Corporation Arrival at South Pier of 10 NS, SD

Operations with Modular Hybrid Pier

Corrosion and Corrosivity Monitoring System (C2MS)

Product Description: Galvanic and corrosivity sensors to• monitor critical bolted assembles • monitor corrosivity of environment in

hidden/hard-to-access areas of aircraft• provide diagnostics/ prognostics and

recommended maintenance actions

Installation on H-60

Payoff:• Life cycle savings $100M• Improve flight safety• Improve flight readiness

Wide Area NDI Imaging Technology

Product Description:Integrated Thermography and spectral imaging system for detecting subsurface defects and corrosion under paint without paint removal

IR CAMERA

FLASH HOOD(small versionshown here)

POWER SUPPLY

DATAACQUISITION

SYSTEM

COMPUTER /PROCESSOR /

DISPLAY MINI-DISPLAY

Preflash

CORRODED UNCORRODED

Payoff:• Life cycle savings $60M• Faster, more reliable

inspection• Lower repainting costs & less

HAZMATField tested the first Prototype

During flash

Advanced Coatings and Longer-Life Components for USMC Vehicles

Product Description: Test protocol for coating systems applied to Marine Corps vehicles reflecting actual Marine Corps service environment.

Beach site Testing

Over 2700 Al and steel panels are being tested

Payoff:• Life cycle savings $700M• Improved acquisition

specifications • Improved corrosion performance

of vehicle systems and components

• Increased readiness

Coupon Racks

Road Test Methodology

Product Description: Contractually enforceable Corrosion-Durability Road test procedure for Marine Corps vehicles

Combination of Corrosion/Durability Events

Payoff:• Life cycle savings $700M• Improved vehicle corrosion

resistance• Extend vehicle service life to 20

years• Increased vehicle readiness

Summary

• Corrosion Control and Prevention is a top operations and maintenance priority

• High payoff ONR projects are producing viable products with limited program resources – but more needs to be done

• Corrosion research and development is helping:- Reduce O&S corrosion cost to enable fleet

recapitalization and modernization- Extend service life of Navy assets beyond original

design- Increase readiness for present and future missions

while reducing resource requirements