Powder Coating and Flame Spraying Technologies for Maintenance and Sustainment – Phase II

NCMS Project #: 142059

Problem: There are two major problems currently limiting powder coating adoption.  The first issue is a lack of knowledge of how factors such as powder particle size and film thickness affect powder coatings.  The second issue is that some items are not able to be oven cured.

Benefit: Thermal sprayed powder coated surfaces are more resistant to chipping, scratching, fading, and wearing than other finishes.  Durable coatings can then be field applied for buildings and other industrial applications, providing more sustainable finishes and lower maintenance costs.

Solution/Approach: The objective of this initiative is to demonstrate robust thermal sprayed powder CARC application.  Phase I identified the parameters to improve the ability to apply the thermoplastic powder coating in other locations other than conventional ovens and industrial coatings settings.  The Phase II initiative will evolve from laboratory-scale research to depot-scale demonstration and include training for operators on the new powder system application techniques.

Impact on Warfighter:

  • Reduce corrosion 
  • Lower overall maintenance and sustainment costs 
  • Increase longevity of new and old assets 
  • Improve durability and safety 
  • Decrease environmental impacts
  • Expand warfighter readiness and lethality 

DOD Participation:

  • U.S. Army Ground Vehicle Systems Center (GVSC)
  • U.S. Air Force (observer)

Industry Participation:

  • PPG Industries, Inc.
  • NCMS

Benefit Area(s):

  • Cost savings
  • Repair turn-around time
  • Maintenance avoidance and reliability
  • Positive environmental impact
  • Safety
  • Maintenance management improvement
  • Improved readiness
  • Durability
  • Reliability improvement

Focus Area:

  • Coatings/corrosion prevention