Powder Coating and Flame Spraying Technologies for Maintenance and Sustainment
NCMS Project #: 140850
Problem: Because of the inability to achieve the desired finishes, and because of the inability to use large ovens to cure large or odd-sized objects or parts, powder coatings are relegated primarily to interior one-coat finishes. The current industry benchmark for powder coating performance is the automotive industry’s targeted 10-year performance whereas the U.S. Army has systems with intended service lives of 22 plus years. A concern with tactical vehicles is how to reduce life cycle costs of metals finished with powder coatings; results from this effort can then be extended across commercial industries using powder coatings. The military has established a specification for powder coatings, that includes powder coatings for use as a camouflage, chemical–agent–resistant–finish coating.
Benefit: The public benefits include: reducing/eliminating volatile organic compounds (VOCs) emissions; reducing worker exposure to solvents; adding a touch corrosion resistant layer to the vehicle/equipment substrate; reducing the total annual estimated direct cost of corrosion in the U.S.
Solution/Approach: This project will evaluate the impact of key powder application parameters on the performance of the cured coating vs. MIL-PRF-32348 and will optimize powder application parameters/performance: particle size, film thickness, voltage, gun and tip type and bake to enable faster adoption of powder technology.
The objective is twofold:
- Develop robust powder application guidance – particle size, film thickness.
- Develop flame-sprayed powders which will meet CARC requirements and can be extended to commercial use for a variety of products.
Impact on Warfighter:
- Reduce overall maintenance expenses
- Improved equipment readiness
- U.S. Army (TARDEC)
- PPG Industries, Inc.
Technology Focus Area(s):
- Cost savings
- Repair turnaround time
- Maintenance avoidance & reliability