Coating Layer Consolidation

NCMS Project #: 140889

Problem: Traditional corrosion control coating systems, whether industrial or military, include at a minimum, surface preparation, pretreatment, primer, and topcoat. Each of the layers in this “coating stack” must be compatible with prior and subsequent layers. Obtaining additional/enhanced protection is likely to require adding layers to the coating stack. Examples include a zinc-rich primer layer between metal substrate and primer or an anti-chip layer between primer and topcoat. Unfortunately, these added layers would increase coating stack complexity and decrease productivity in production/maintenance. Research is required to consolidate coating layers throughout the stack. This would afford enhanced corrosion protection while minimizing complexity and time spent applying coatings and/or waiting for them to cure sufficiently to add subsequent coating layers.

Benefit: A successful project will result in dual-use corrosion protection strategies that represent cost savings, and improvements to the DoD and the general public through enhanced asset protection. These technologies will be applicable to both defense and industrial applications requiring substrate protection, including but not limited to, ground vehicles, all modes of transportation, aging bridges, buildings, sections of highways, electrical towers, power plants and numerous other structures.

Solution/Approach: The intent of this initiative is to use the U.S. Army’s corrosion issues as a test bed to develop optimized technologies for corrosion resistance and show how such improvements can be transferred to commercial applications such as personal and commercial vehicles, e.g., cars, buses, ships, industrial machinery, farm equipment, oil rigs, or vital, national infrastructure. Research will focus on obtaining optimum corrosion resistance by combining performance attributes from multiple coating layers into a single layer. This will enable enhanced protection without negatively impacting depot productivity. The ability of novel techniques and/or materials to provide enhanced substrate protection will need to be validated and quantified according to military and industry standards to determine whether the modifications to currently-approved coating materials or protocols is justified.

Impact on Warfighter:

  • Reduced maintenance costs
  • Improved readiness
  • Increased coating longevity

DOD Participation:

  • U.S. Army
  • Army Research Lab

Industry Participation:

  • PPG Industries
  • North Dakota State University
  • NCMS

Benefit Area(s):

  • Cost savings
  • Repair turn-around time
  • Maintenance avoidance and reliability
  • Positive environmental impact
  • Improved readiness

Focus Area:

  • Coatings/corrosion prevention