Corrosion Prevention & Control (CPC)

The June 2024 Issue of the US Air Force Corrosion Prevention and Control Office Newsletter covers:
• 2024 Corrosion Technical Interchange Meeting and Air Force Corrosion Manager of the Year Award (CMOTY) Award
• Feb 2024 Aerospace Systems Corrosion Control Working Group (ASCCWG)
• Advanced Technology and Training Center (ATTC) Highlight
• List of Upcoming Conferences
• Facility Design Review Information

Welcome to the Corrosion Prevention & Control Page on Previous and Upcoming Conferences!     There are several corrosion related conferences throughout the year. The DoD Allied Nations Technical Corrosion Conference is held biennially on odd numbered years. Please see documents below from previous conferences.

​Training Policy & Impact of Corrosion Standards Congressional Engagement Conferences Integrated Product Teams Projects & Technology Transition Facilitites Information Sharing

2023 DoD Corrosion Prevention Technology and Innovation Symposium

Accelerated & Outdoor Exposure Testing

Title	Author	Summary
Naval Aviation Environmental Severity Correlation	Christine E. Sanders, Raymond J. Santucci, Jr., Christina M. Stewart, Sheri L. Stanke	Naval Research Laboratory (NRL)-Key West is a state-of-the-art testing facility for atmospheric and marine corrosion. The site naturally has elevated UV intensity, similar to operational areas for the Navy. Recently, the testing capabilities were expanded to include the ability to rinse samples with clear water (to mimic preventative maintenance washing), to shelter samples within a protective aircraft cover (to mimic preventative maintenance storage), and to spray samples with seawater (to increase the severity of the exposure). It is hypothesized that the Key West site can be tuned to mimic the exposure conditions of other sites of relevance to Navy operations.
Environmental Modification and Atmospheric Corrosion: Clear Water Rinsing, Covering, And Seawater Spray	Christine E. Sanders, Raymond J. Santucci, Jr.	There is far-reaching interest in the DoD to better characterize the impacts of clear water rinsing and handwashing in different operational conditions. The Naval Research Laboratory’s outdoor testing facility in Key West, FL was chosen as a test site expose samples to multiple modified conditions within the same ambient environment. The effect of select environmental parameters on the atmospheric corrosion of steel (via mass loss) and silver (via galvanostatic reduction) was assessed. The effect of clear water rinsing was evaluated by rinsing all samples with tap water thrice a week, once a week, or naught at all. Clear water rinsing is consistent with current preventative maintenance strategies. The effect of covering was tested by sheltering a set of samples underneath a canvas shelter, consistent with aircraft covering currently used, which precluded interaction with precipitation and sunlight. The effect of natural sea water spray was tested on select samples by spraying them either once a day or twice a day. All conditions were compared against the ambient exposure condition (the natural environmental profile of Key West). The role each parameter plays in the corrosion process is discussed. Overall, a better understanding of clear water rinsing emerges. This effort will serve to better inform aircraft maintenance routines, strategies, and resources.
Evaluation of FeMnAl for Corrosion Protection & Coating Performance	Lindsey Blohm, Krista Limmer	FeMnAl, a ferrous alloy containing large amounts of manganese (Mn) and aluminum (Al) is under consideration for use in Army systems and is subsequently being investigated for corrosion performance. FeMnAl has the potential to be utilized as an alternative for structural steel. An electrochemical investigation of 12 alternate FeMnAl compositions was performed in 0.1M H2SO4 electrolyte, showing only minor changes in the corrosion potential. Mass loss was also performed in ASTM B117, showing FeMnAl alloys to be comparable in corrosion performance to structural steel. Work has also been performed to evaluate FeMnAl’s coating performance following pretreatment and coating application. This work includes four pretreatments with MIL-DTL-53022 in ASTM B117, GMW 14872, and ongoing outdoor exposures top coated with MIL-DTL-53039 at Cape Canaveral Space Force Station.
Considerations For Laboratory Corrosion Fatigue Testing Of Aluminum Alloys For DoD Applications	Sarah E Galyon Dorman, Justin Rausch, Nathan Houser, Jenifer (Warner) Locke	This project aims to develop an accelerated environmental fatigue crack test method. Natural changes in temperature and relative humidity during in-flight and nocturnal/diurnal cycles have shown wetting and drying. The goal of this project is to better understand the effects of this cycling on corrosion fatigue. This method would be used for evaluating newer aluminum alloys and corrosion coatings with respect to their effect on environmentally assisted fatigue. Changes occurring in the fatigue crack growth rate (FCGR) are measured to determine the effect of simulated atmospheric environment. Complex wetting and drying effects are known to occur under atmospheric corrosion conditions. It is thought that these conditions also accelerate environmentally assisted cracking.
Real-Time Measurement Of Aerospace Coating Condition And Detection Of Corrosion Protection Change Point For Predictive Coating Condition Modeling	Brandi Clark, Victoria Avance, Liam Agnew, Fritz Friedersdorf, Matthew Repasky, Henry Yuchi, Yao Xie	Organic aerospace coatings are the primary means of protecting aircraft from atmospheric corrosion in harsh environments. To improve condition-based maintenance of coated assets, there is a recognized need for predictive coating condition models to make service life predictions in environments of varying severity. However, model development and validation may be limited by the ability to quantify time to failure in laboratory tests. The goal of this work was to quantify the transition from protective to nonprotective condition for scribed aerospace coatings in a standard cyclic accelerated corrosion test. Specifically, this work evaluated the ability of time to failure metrics calculated using continuous measurements of galvanic corrosion to (1) differentiate coating performance and (2) align with visual coating evaluation metrics. A description of the monitoring devices, electrochemical measurements, and methods for coating testing are reported along with the analysis of the resulting data and its implications for predictive coating condition model development.
Gravelometer For Coating Holiday Generation And Acceleration Of Corrosion Initiation	Ivan Stanke, Christine E. Sanders	Quantification of gravelometer equipment is a time-consuming process. The information contained with in should be used by DoD programs to help narrow the parameters for testing to avoid extensive operational equipment time, and therefore cost. This information should be beneficial to multiple DoD user groups from Army and Marine Corp ground vehicles to NAVY and AIRFORCE aerospace and any maintenance group that operates in an environment where dust and rock impacts occur. The U.S. Naval Research Laboratory (NRL) was tasked by NAWCAD Air Systems Group Material Protection Technology Branch with examining the use of ASTM D3170 gravelometer equipment to generate impact damage for evaluation. The gravelometer is a useful tool for quickly generating impact damage on coating test samples. Five media types were examined over the operational pressure range of the gravelometer.
Comparative Analysis Of Cold Spray AA7075 And AA2024 Corrosion Behavior In Accelerated Laboratory And Outdoor Test Environments	Gregory W. Kubacki, Ozymandias Agar , Rachel E. Black, Steven P. Kopitzke, Christine E. Sanders, Sheri L. Stanke, Raymond J. Santucci, and Luke N. Brewer	Cold gas dynamic spraying (cold spray) is a promising technology for in-situ additive repair of military assets, particularly where previous corrosion damage has occurred during service. Cold spray is a solid state additive technique that can generate rapid, high-density coatings with minimal heat input to the substrate, which is critical for aerospace aluminum. In this work, we aimed to assess the environmental behavior of cold spray deposited AA7075 and AA2024 in both simulated, blend-out repair and bulk (robotically-deposited flat-on-plate) deposition geometries in GMW 14872 and coastal exposures with or without acceleration by applied seawater spray. Simulated repair and robotically-generated flat deposits were exposed to 1824 hr GMW 14872, 6 mo coastal exposure accelerated with twice daily seawater spray, and 18 mo ambient coastal exposure. Samples were conversion coated and some included stainless steel fasteners. Corrosion damage was assessed via mass loss, profilometry, and metallography and compared to wrought controls.
Accelerated Corrosion Test Control And Monitoring	Sean Fowler, William Tobin	Accelerated corrosion test method innovations in the automotive industry are working their way into other industries, including defense and aerospace. Precisely controlled relative humidity and high volume direct spray of electrolytic solutions are two innovations of note. Quality control of these new methods is challenging because monitoring the RH in a highly corrosive environment is difficult. Corrosion rate measurement of bare metal panels is traditionally used for quality control during a test, but the techniques are time consuming and difficult. Additionally, quantifying the amount of high volume spray required for good test reproducibility is not as well-understood as for fog type methods such as ASTM B117. This paper will explore both topics with the goal of introducing these innovations to a new audience.
Evaluation Of Corrosion-Resistant Alloys For Use In Acidic And Marine Launch Environments At NASA Kennedy Space Center: 20-Year Study	Eliza L. Montgomery and Michelle Pierre	After the completion of an initial three-year study to qualify corrosion-resistant stainless steel tubing for use in NASA Kennedy Space Center’s acidic and marine launch environment, test specimens remained exposed at the KSC Beachside Atmospheric Corrosion Test Site for long-term exposure. NASA KSC’s lifetime requirement for most ground support equipment is twenty years. After twenty-one years of marine exposure, NASA KSC took the unique opportunity to reevaluate the tubing after long-term exposure to better understand the corrosion resistance of these alloys as they reached their expected lifetime requirement. Metallurgical and corrosion analysis was performed on the CRES tubing components and the alloys were rated on performance. A summary of CRES alloy tubing corrosion-related performance after 20 years of exposure in a marine launch environment is presented in this work.
Long-Term Corrosivity At NASA Kennedy Space Center As A Function Of Distance And Time From The Atlantic Ocean	Eliza L. Montgomery, Michelle S. Pierre, and Mya M. McMullen	Long-term data to record both seasonal and notional bounding values for corrosivity at multiple sites at NASA Kennedy Space Center was needed to make better materials choices for NASA-based ground and spaceflight programs. The data was valuable for two key reasons, 1) to measure corrosion rate and chloride concentration as a function of time and distance from the Atlantic Ocean, and 2) compare the corrosivity at launchpad and site-specific areas to the more accelerated conditions at the KSC Beachside Atmospheric Corrosion Test Site for coating and materials performance prediction. Sites were chosen from 45 meter (150 feet) to 8 kilometers (5 miles) from the Atlantic Ocean and corrosion variables at each site were measured throughout each year from June 2017 to April 2023, except the Beachside site, which includes data from November 2010. The summary includes corrosion rate and chloride concentration values, which will be used as the updated NASA corrosivity standard for corrosion control requirements.

Corrosion Sensor/Paints & Coatings

Title	Author	Summary
Qualification and Demonstration of Oxsol-Free and Low-VOC Topcoats for Surface Ships and Submarines	Danielle Zuk, James Tagert, Erick Iezzi, Bruce Connelly, Timothy Langaster, Tim Wise	This paper summarizes the qualification results and demonstration plan of Oxsol-free coatings for surface ship and submarines. Oxsol 100 is a popular solvent for use in military and commercial coatings as it does not degrade ozone and is considered an exempt solvent by the Environmental Protection Agency (EPA). It is also the only volatile organic compounds (VOC) exempt solvent with a flash point >100 °F. The new polysiloxane topcoat formulations, which are Oxsol-free, isocyanate-free, low in VOCs, and free of hazardous air polluting (HAP) solvents, are based on non-hazardous raw materials and will be formulated as single-component (1K) and twocomponent (2K) systems. This work is funded by the Department of Defense Environmental Security Technology Certification Program (ESTCP).
Evaluation Of Methods For Corrosion Prevention Within Steel Enclosed Spaces	Evan Winick, Tom Sanders	There is a need for corrosion prevention methods that will work inside inaccessible cavity areas to prevent corrosion of assets from the inside-out. Newly fielded assets may have electrocoat (e-coat) applied in these areas, but this technology has not yet made it to the majority of the fleet. Various groups within the DoD (including PMs, field personnel, maintainers, and depot personnel) have expressed interest in instituting corrosion prevention methods for use inside cavities on multiple ground support equipment platforms
Perceived Color Differences In Relation To Film Build	Morgan Brookens, Lauren Paladino, Andrew Sheetz, Jake Rovner	Upon inspection of completed asset repairs at USMC Corrosion Repair Facilities, a common issue was noted with visible inconsistencies following application of camouflage coatings. These inconsistencies were streaks of distinctly different light and dark colors within the same color band. Despite several efforts to eliminate the issue by the CRF personnel, the color inconsistency remained. The USMC CPAC RDT&E program undertook an effort to both understand and develop a method for preventing the perceived color differences from occurring in the field.

Corrosion Fundamentals

Title	Author	Summary
Impact of Calcareous Deposits on Current Distribution and Electric Field Rearrangement	Caelen Clark, Matthew Storm	This work characterized the time evolving impact of mineral deposit formation on the current distribution across cathodically protected surfaces with different charge transfer properties. A custom scanning tank apparatus for the measurement of electric field rearrangement during cathodic protection was utilized. A concentric ring-disk arrangement was utilized to establish a simple non-uniform current distribution across a 14-cm diameter electrode surface. Baseline electric field measurements were conducted in 0.6M sodium chloride, and mineral deposits were formed in artificial seawater over a 180-hour period. Only minor differences were observed in the current distributions on both materials in sodium chloride. However, time dependent changes in current distribution across the electrode surface caused by the formation of mineral deposits were observed for both electrode materials. This work shows that both primary current distribution and the influence of mineral deposition needs to be considered when designing a steady state seawater cathodic protection system.
Evaluation And Optimization Of Localized Corrosion Behavior Of Cold Spray Deposited AA2024	Gregory W. Kubacki, Ozymandias Agar, Luke N. Brewer	Cold-gas dynamic spraying (CS) is a promising solid state additive manufacturing technology to produce in-situ repairs to damaged DoD systems. A key feature to deploying this technology in the field is the relative corrosion behavior compared to traditional, wrought or extruded alloys. Currently, there is limited knowledge on the localized corrosion initiation and propagation mechanisms in cold sprayed aerospace aluminum, particularly in the context of how spray parameters may affect these behaviors in repairs. This work aims to compare localized corrosion susceptibility of cold spray deposited AA2024 to its wrought counterpart and evaluate the role of deposition parameters in the optimization of corrosion performance. Electrochemical tests, immersion experiments, and materials characterization techniques were combined to evaluate the pitting initiation and propagation mechanisms in cold spray AA2024. Additionally, we compare macroscopic pitting behavior under full immersion in artificial seawater for 5 days across a range of cold spray parameters to assess the potential for optimization of pitting resistance.
Overcoming Wear-Enhanced Corrosion Through Alloying In AM Stainless Steels	Mary E. Parker, Andrew J. Birnbaum, Anna K. Rawlings, John C. Steuben, Kathryn J. Wahl, Derek J. Horton	Tribocorrosion testing was applied to a compositionally and microstructurally varied austenitic stainless steel that was fabricated using a directed energy deposit (DED) additive manufacturing (AM) method. Elemental and microstructural characterization showed that composition and hardness varied in the build direction of the specimen due to mixing with the base metal, ranging from an AL6XN super austenitic base metal to additively manufactured (AM) 316L. This approach allowed efficient screening of the impact of composition and hardness on the tribocorrosion response of austenitic stainless steel.
Stress Affected ORR On Stainless Steel	Carlos M. Hangarter, Rachel M. Anderson, Steve A. Policastro	This work reports the impact of tensile stress upon oxygen reduction reaction (ORR) for a stainless steel fastener material UNS S13800. Chronoamperometry was used to observe and quantify the influence of tensile stress profiles on ORR under NaCl droplet electrolytes. NaCl was utilized as a seawater proxy at concentrations of 0.6 M NaCl and 4.6 M NaCl, the latter corresponding to 80% relative humidity, which is near the deliquescence point for NaCl. The ORR current was shown to increase with tensile stress and displayed reversible behavior with simple stress profiles. Deoxygenated experiments were performed to isolate ORR contributions from oxide dynamics. Details of current transients during strain ramping are used to demonstrate these features are distinct from the ORR current shift observed during static tensile stress. EIS and Mott-Schottky experiments were conducted to gain insight into the mechanistic behavior of stress induced ORR current changes. Results for thin film electrolyte indicate the stress has a larger influence upon ORR in atmospheric environments.
Navy Turbine Engine Corrosion: Understanding And Mitigation	David Shifler	High temperature applications demand materials that have a variety of properties, such as high strength, toughness, creep resistance, fatigue resistance, as well as resistance to degradation by corrosion and/or oxidation. Understanding these high temperature mechanisms can subsequently lead to designing corrosion resistant materials or apply protective measures will permit enhanced performance, capabilities, and efficiency improvements. A multidisciplinary systems approach needs to resolve the critical drivers that influence the performance and life of materials and coatings at high and ultrahigh temperatures (700 to  1500ºC). This creates multiscale, multivariable physics and chemo-mechanical based models and tools to establish the fundamental science base for ultrahigh temperature material systems that can survive various Naval environments over a wide range of temperature-stress– environment–time variable fields that may be encountered.
Effect Of Humidity And Salt Concentration On Corrosion Of AA2024-T3 Alloy	Patric Helbig, Andy Dutch	In order to determine what levels of salt accretion on aircraft would have no significant effect (acceptable) and would have low levels of effect on aircraft surfaces (tolerable) Aluminium AA2024-T3 coupons had varying salt surface densities applied to their surface and were exposed to four different humidity settings in a controlled environment at a constant temperature. Post exposure all corrosion product was removed and several different methods to quantify corrosion intensity were assessed. It was demonstrated that volume loss and maximum pit depth proved to be effective metrics to quantify the increase in corrosion with an increase of salt surface density. Humidity vastly increases the propensity for salt to cause corrosion. From those results acceptable and tolerable salt levels for aircraft structures were determined.

Corrosion Inhibitors

Title	Author	Summary
Use Of Migratory Corrosion Inhibitors For Service Life Extension, Reduction In Use Of New Concrete For Repairs And Decrease In Downtime For Facilities Vs Alternative Methods Of Repair.	Julie K. Mizzi	This paper examines the use of migratory corrosion inhibitors (MCIs) in extending the service life of concrete structures, reducing the need for new concrete repairs, and minimizing facility downtime compared to alternative repair methods. This paper will analyze the performance of MCIs in the military concrete facilities and compare them with other repair techniques, such as concrete patching, coatings, and cathodic protection alone. The results will provide insights into the most effective and sustainable approach to maintaining and extending the service life of concrete structures while minimizing downtime and material consumption.
Mold And Mildew Prevention On Exterior CARC	Kyle Hershman, Charles Machi, Evan Winick	This study explored the effectiveness of Commercial Off-The-Shelf (COTS) products and their ability to remove and prevent mold growth on the Chemical Agent Resistant Coating (CARC) system. Testing of the COTS products took place in both a laboratory-controlled setting and on in-service US Army assets. Laboratory testing was conducted on CARC coated samples IAW ASTM D3274 modified by the application of agar directly to the samples to allow for growth under the recommended chamber conditions.1 The COTS products were used per the manufacturer’s recommendations to clean the surface of mold and/or prevent its growth. The ability of each product/method to clean the surface as well as the regrowth of mold was verified visually under ambient and black-light conditions, with the percentage of the area covered used to demonstrate relative effectiveness. Field demonstrations were carried out at Joint Base McGuire-Dix-Lakehurst, NJ, where the best performing COTS removal techniques from the laboratory testing were used to remove existing mold from four US Army assets. This paper provides commentary on the top performing COTS products, as well as the lessons learned about the mold prevention and removal from CARC coated assets.
Evaluation Of Corrosion Rate In Common Commercial Inhibitors For Mixed Metal Coolant Loops	R.M. Anderson, J.S. Lee, D.J. Horton, R.G. Kelly, E.J. Lemieux	Coolant loops often contain mixed metals that require appropriate corrosion control to maintain system reliability. Galvanic corrosion effects and broad interactions between components within the loop are important considerations. Furthermore, readily available commercial inhibitor packages are proprietary and only broadly defined by their manufacturer as suitable for different types of materials and are usually not designed for the specific metal combinations or their respective wetted surface areas.

Corrosion Modeling

Title	Author	Summary
Using Machine Learning Techniques To Estimate Initial Model Parameters	Steven A. Policastro, Attilio Arcari, Carlos M. Hangarter, E.B. Iezzi, and R.M. Anderson	Two machine-learning models were trained on a set of electrochemical impedance spectroscopy (EIS) data obtained from a commercial aircraft coating system applied to test coupons placed in laboratory environments that simulated  outdoor exposure conditions. The EIS data was fit with the coatings equivalent circuit model using different initial parameter estimates to form the training datasets. The newly trained models were then included as a preprocessing step in the Levenberg-Marquardt nonlinear regression method for the equivalent circuit model fit. Comparing the outcomes between the original algorithm and the one using the machine-learning (ML) models indicated a ˜50x increase in performance.
Effect Of Environmental Conditions On The Catalytic Behavior Of A Stainless-Steel Oxide	Steven A. Policastro , Carlos M. Hangarter, Rachel M. Anderson	Galvanic couples between high-strength, noble metal fasteners, such as those made from stainless-steel, can cause extensive damage in aluminum alloy airframes. These galvanic couples can drive higher rates of oxidation reactions than would be expected for general corrosion and the corrosion damage can become a stress concentration point for the nucleation of cracks. Understanding the factors that govern the catalytic activity for the oxygen reduction reaction on stainless-steel oxides is important for enabling predictions of the amount of corrosion that can occur for a given set of environmental conditions. We have focused on measurements of the diffusion limited current density for oxygen reduction on UNS S13800 stainless-steel in solutions of varying NaCl concentrations from 0.01 M to 5.2 M and air temperatures ranging from 5 to 45 degrees C. Estimates of the oxygen diffusion limited current were obtained from potentiodynamic polarization measurements under the various electrolyte concentrations and environmental conditions. The experimental data was then compared with calculated ilim values for the same conditions and assuming a constant diffusion layer thickness. Regression and physics-based models for the effect of environmental conditions on the experimental data have been developed and are used to simulate the response of the stainless-steel oxide for a variety of environmental conditions. The results presented in this paper demonstrate another tool for the corrosion researcher to use to extract kinetics information from polarization curve data.
Development And Testing Of A Corrosion Management System	A.R. Trueman	A corrosion management system was developed to predict atmospheric corrosion for general and localized corrosion of steels and aluminum alloys. The system can be extended to other materials and corrosion types. The corrosion management system is at an advanced prototype stage, with more work required, mainly in the software components, and is currently being commercialized. The system consists of two components: a Corrosion and Environmental Monitoring System (CEMS) that collects environmental data using deployable sensors and datalogging equipment, and the Atmospheric Corrosion Modelling software (ACM) that uses the CEMS data as well as meteorological and pollutant deposition data, available online, to make corrosion predictions. These corrosion predictions are not based on empirical corrosion data, nor corrosion sensors that are difficult to translate into structural corrosion rates.
Modeling And Property Measurement Tools For Corrosion Resistant Aircraft Design And Maintenance	Rebecca Skelton- Marshall, Victoria Avance, Liam Agnew, Brandi Clark, and Fritz Friedersdorf	In this work, potentiodynamic scans (PDS) were generated in environments representing aircraft service conditions, to inform an open-source finite element method (FEM) corrosion model. Specifically, rotating disk electrode PDS were conducted to represent thin-film atmospheric conditions, in contrast to conventional immersion PDS as described in MIL-STD-889D. Samples designed to represent a butt joint and capable of measuring real-time galvanic corrosion were placed outdoors to verify and validate the corrosion model. Two galvanic couples were the focus of this work, AA7075/CFRP and AA7075/Ti-6Al4V. To act as a complimentary tool to the FEM corrosion model, an interactive web application based on the galvanic compatibility in MIL-STD-889D was constructed. A description of the atmospheric PDS collection, outdoor exposed galvanic corrosion samples, and the modeling approach will be reported, as well as a comparison between experimental measurements and computational predictions.
Predictive Corrosion Models To Mitigate Environmental Hazards On Ground Assets	James Ellor, Daniel Pope, Anthony Florimbio, C. Thomas Savell, Lisa A. Barker, and John Repp	The research updates ongoing efforts to develop a predictive model for coating degradation and substrate corrosion on Army assets. The model incorporates the learning from field surveys of over 15,000 assets and 250,000 components; coating performance in standardized testing; and observations of coating condition as applied to fielded items. The model outputs would provide a basis to (1) support a Commodity Manager to determine repaint intervals, optimizing expenditures and (2) develop new products/processes (impacting coating performance) increasing the life of an asset protective coating system.
Integrating Corrosion Modeling With Digital Engineering	Richard J. Thompson, Kristen Williams, Ethan Moore, Ahmad Ivan Karayan, and Tyler Smith	Digital engineering methods, including digital thread and model-based systems engineering (MBSE) offer significant reductions in the development of new vehicle platforms and are becoming more commonplace. The Dept of Defense Digital Engineering Strategy published five target goals in 2018 to streamline acquisition through the creation of a digital thread. However, despite this recent emphasis, materials selection for aerospace corrosion prevention and control (CPC) is still typically performed through testing coupled with engineering judgment. Qualification of new materials is based on a combination of extensive testing, on-aircraft demonstration or empirical modeling of service life, often without an understanding of the underlying corrosion mechanisms. Few aerospace-specific MBE tools are available for supporting this digital thread approach to include corrosion and its impact to vehicle service life. This paper presents a summary of corrosion modeling activities across Boeing and recent efforts to incorporate these models into an enterprise MBE framework.

Corrosion Monitoring & Assessment

Title	Author	Summary
Salt Deposition On F-5 Aircraft In Various Service Environments	Christine Sanders & Christine Stewart	Conductivity testing, via Bresle patch analysis, was performed on F-5 aircraft in Key West, FL, Fallon, NV, and Yuma, AZ to compare the level of salt contamination present at each location. The inspection locations were selected based on the observations of the pilots and maintenance staff of VFC-111, the squadron stationed in Key West, FL. The selected locations represented the areas of highest concern and recurring problem areas noticed by maintenance staff. Testing was performed at several points during the flight schedule: before the first flight of the day, following a flight, and prior to and following a scheduled clear water rinse event. The results obtained from Key West, FL and Fallon, NV indicate a large discrepancy in the amount of salt contamination present in the two locations, with Key West yielding much higher readings. These results lead the researchers to believe that the aircraft in residency in Key West should be treated in similar fashion to those maintained aboard aircraft carriers, including more frequent wash and inspection cycles, and potentially proper marinization of the aircraft with marine specific coatings.
Efficacy And Corrosion Risk Of Chemical Disinfectants For Military Aircraft	D. Buhrmaster, R. Krabacher, C. Bojanowski, M. Barga, C. Sanders, E. Sheridan, M. Rothgeb, J. Crafton, W. Kessen, S. Kopitzke, K. Canales, V. Molina, C. Stewart, S. Riley, S. Stanke	The severe acute respiratory syndrome coronavirus 2 (SARS-CoV-2, aka COVID-19) pandemic led to high interest in rapid disinfection methods using sprayed chemicals on military aircraft interiors and infectious disease containment units. Many commercial disinfectant manufacturers made claims of laboratory evaluations for efficacy against SARS-CoV-2 surrogates and of aerospace materials compatibility based upon testing for commercial aircraft. Early DoD results showed that these manufacturer claims were not sufficient for military applications. At the time, there was no suitable efficacy or materials compatibility First Article verification protocol to determine that these disinfectants would kill the virus but cause no harm to military assets, particularly military aircraft interiors, flight decks, and rapid deployed containment units.
Quantifying How The Removal Of Corrosion Prevention Methods Impact Fastener Hole Systems	James A. Ellor, Daniel Pope, Anthony Florimbio, C. Thomas Savell, Lisa A. Barker, John Repp	The research updates ongoing efforts to develop a predictive model for coating degradation and substrate corrosion on Army assets. The model incorporates the learning from field surveys of over 15,000 assets and 250,000 components; coating performance in standardized testing; and observations of coating condition as applied to fielded items. The model outputs would provide a basis to (1) support a Commodity Manager to determine repaint intervals, optimizing expenditures and (2) develop new products/processes (impacting coating performance) increasing the life of an asset protective coating system.
Augmented Reality Enhanced Corrosion Control Systems	Dan Ketchen, Leighton “Todd” Lavender	Systems for detecting and measuring corrosion have been around for decades, but while their sensing accuracy has improved over time, the human factors aspect of these systems have not kept pace. The research team identified an opportunity to increase efficiency, lower cost, and increase the safety of Corrosion Control professionals by enhancing existing corrosion control detection and measurement systems with wearable Commercial-Off-the-Shelf Augmented Reality technology to provide data as a visual overlay within the user’s field of view, tag measurement data in Three Dimensional Space to specific aircraft, save data for future use and users, and export data and live video to additional users and digital twins. The Team enhanced two systems: one which measures the thickness of paint on a metal or composite substrate and an Eddy Current Non-destructive Testing system. Both projects were funded by the United States Air Force and leveraged collaboration with 402 AMXG Corrosion Control at Warner Robins Air Logistics Complex, resulting in approved prototypes ready for deployment to any vehicle maintenance or manufacturing facility. The approach was estimated by the Government to provide benefits in efficiency, end user safety, and cost.
Detecting Ship Hull Corrosion Above And Below	Kenneth C. Crawford	The purpose of this paper is to present the results of a series of NDT (non-destructive testing) corrosion detection tests conducted at the Canadian MOD Corrosion Sandbox in April 2022, in Halifax, Nova Scotia. The Sandbox objective was to find new technologies capable of identifying hidden corrosion in naval ships. The NDT procedure by the author used small impact machines to conduct tests on a variety of ship deck and hull steel plate configurations to identify changes in steel plate thickness caused by corrosion. This is a new technology. Using the impact-echo technique small wheeled and magnetic-tracked impact machines produce a series of impact impulses across a scanned area of a ship’s hull. The recorded impulses are analyzed for changes in frequency indicating changes in steel plated thickness caused by corrosion. At the Halifax MOD Sandbox impact tests were conducted on nine steel plate assemblies and the MCDV Goose Bay. Proof of concept was achieved when the impact machines produced different frequencies for varying plate thicknesses. NDT results in this research paper show the impact-echo technique can identify ship hull corrosion. The ship’s entire hull above and below water can be scanned by an operator and its steel condition recorded in a data base and plotted on engineer drawings for future repair.

Corrosion Policy

Title	Author	Summary
NEW Army Regulation Army Corrosion Prevention And Control Program (AR 11-42)	Courtney Guasti, Yusra Anwar	The Army’s Corrosion Control and Prevention Executive (CCPE) Office has been working to overcome a shortage of adequate data on corrosion and its effect on Army materiel. As evidenced by maintenance data, the Army has shifted from a reactive to a more proactive approach in mitigating and preventing corrosion. To both fill corrosion data gaps and mitigate corrosion, the Army funds survey teams operated by lifecycle maintenance commands (LCMCs). These survey teams provide insight into critical corrosion gaps occurring on the field related to training, equipment maintenance, standard operating procedures and facilities. Compared to correction, prevention is the optimal method by which to manage corrosion. Over the last decade, the Army has been shifting towards more expenditure on preventative maintenance versus corrective maintenance. In order to delegate roles and responsibilities regarding corrosion, the Army published AR 11-42, which implemented the Army Corrosion Prevention and Control Program. Additionally, AR 11-42 defines policy on incorporating corrosion prevention and mitigation requirements from design through sustainment activities and established procedures for Corrosion Action Memorandums (CAMs) to ensure findings from surveys result in meaningful action.

Corrosion Prevention & Control Strategies

Title	Author	Summary
Designing For Affordable Corrosion Control In Marine Environments	David A. Shifler	Materials and equipment that function in the marine environment are subjected to aggressive conditions. Salt is pervasive in all the marine environments. Corrosion is a leading driver for maintenance and overall lifecycle costs. Proper material choices, corrosion control measures, and employing effective design to avoid corrosion are the most effective means to reduce maintenance and life cycle costs. Design decisions are seldom absolute. When designing a system, multiple factors should be considered, some of which may override corrosion concerns. A designed component or system must satisfy its functional purpose, but corrosion may occur at critical sites that interfere with its true functionality.
Installation And Qualification Of A New Zinc-Nickel Plating Line	Alexander J. Nicoloff	Fleet Readiness Center Southwest (FRCSW) is a leading depot rework site for US Navy and US Marine Corps aircraft, located in San Diego, CA. The depot operates an extensive electroplating and surface finishing facility as part of the Department of Defense (DOD)’s maintenance, repair, and overhaul program for critical aviation assets. The facility serves the electroplating and surface finishing needs for F/A-18, E-2, C-2, H-53, H-60, and V-22 aircraft components. In 2022, FRCSW began the installation of a brand new zinc-nickel electroplating line, a $5 million capital investment that broadens the inorganic coating capabilities of the facility. The installation was completed in early 2023, and builds on the work already done by other DoD maintenance facilities, including at Naval Air Station Jacksonville, Hill Air Force Base, and Warner Robins Air Force Base. Implementation of this plating line furthers the availability of zinc-nickel as a cadmium replacement for DoD aircraft maintenance activities. This paper will discuss the background of zinc-nickel plating, the unique technology and design used in the new plating line, and observations and lessons learned during implementation and qualification testing.
Challenges In Operating A DoD Electroplating Shop	Brian K. Gibson	Fleet Readiness Center Southwest (FRCSW) is a leading depot rework site for US Navy and US Marine Corps aircraft, located in San Diego, CA. The depot operates an extensive electroplating and surface finishing facility as a part of the Department of Defense (DoD)’s maintenance, repair, and overhaul program for critical aviation assets. The facility serves the electroplating and surface finishing needs for F/A-18, E-2, C-2, H-53, H-60, and V-22 aircraft components.
Salt Accretion And Aircraft Washing – Surveying The UK MOD Fleet	Patric Helbig, Andy Dutch	Salt accretion measurements were obtained from aircraft based at maritime, non-maritime and embarked locations to better define the risks to aircraft in all operating environments. The work was able to confirm that the risk of salt accretion is significantly higher while embarked. Salt contamination increases towards the rear and lower parts of aircraft and helicopters tend to have higher salt loading than fixed wing aircraft. Efficiency of salt removal during washing decreased for aircraft with low prewash salt contamination. Hotter climates lead to higher salt accretion. In-situ salt contamination can be reliably measured enabling on-condition washing which in some circumstances could result in a significant saving of maintenance workhours. In addition, this work identified achievable post wash salt levels on shore-based aircraft and those operating in maritime and embarked environments from the 90th percentile of these values. These are used to derive As Low As Reasonably Practicable (ALARP) levels of post wash cleanliness. The work in this report is used to inform the second of our reports at this conference which looks to establish acceptable and tolerable levels of salt on AA2024-T3 structures.
Electro-Osmotic Pulse (EOP) Technology for Control of Water Seepage in Concrete Structures	Vincent F. Hock, Heather E. Creason, J. Chad Pierce, and Michael K. McInerney	Groundwater intrusion through a building’s foundation that causes structural damage requires immediate action. In problem areas, the usual approach is to “trench and drain,” that is, to excavate to expose the wall area and the base of the foundation, and then to replace damp proofing on the wall surface and to install a drain tile system around the building or affected area. This process is expensive and can be further complicated by the fact that most contractors limit their warrantees against future seepage in areas with high water tables. Electro-osmotic pulse (EOP) technology offers an alternative to the trench-and-drain approach by mitigating water-related problems from the interior (negative side) of affected areas without the cost of excavation. EOP technology can also mitigate corrosion damage to mechanical equipment and improve indoor air quality by controlling the relative humidity (RH) on the interior wall and floor surface at a level below 55 percent, thus eliminating mold and bacteria growth.

Corrosion Resistant Metallic Alloys

Title	Author	Summary
Crevice Corrosion Initiation Time Of Duplex Stainless Steels 2205 And 2507 In Natural Seawater	Michael J. Hutchison, Mary E. Parker, Rachel M. Anderson, and Derek J. Horton	An accelerated testing method was used to measure crevice corrosion initiation times for two duplex stainless steels as a function of applied potential. Custom experimental equipment created crevice geometries with compliant materials at controlled contact pressures suitable for long-term testing in seawater. This approach quantified initiation times in natural seawater for 2205 (UNS S32205) and 2507 (UNS S32750) in contact with several polymeric materials. Crevice corrosion initiation was not observed in 2507 for any test in natural seawater up to +300 mVAg|AgCl, but 2205 was susceptible to crevice attack. Initiation times for 2205 decreased with increasing applied potential. In long-term natural seawater exposure, both materials ennobled to elevated potentials, in excess of +300 mVAg|AgCl|NSW, due to an electrochemically-active biofilm, leading to initiation on 2205 but not 2507. The presence of a large external cathode area did not clearly correlate to crevice corrosion propagation, partially due to limitations in the experimental approach. The impact of external cathodic support on crevice corrosion initiation and propagation is discussed.
The Effect Of Marine Exposure Condition On Fracture Toughness Of High Strength Alloys	Attilio Arcari, Derek J. Horton, Mary E. Parker, Matthew E. McMahon, Ramgopal Thodla, Ryan A. McCoy	The susceptibility of UNS N07718 produced to different specifications is being studied in detail, including API 6ACRA and AMS 5663, 5664, and 5962. UNS N07718 is a precipitation hardened (PH) alloy and is extensively used in marine environments, particularly in the API 6ACRA and 5664 variants. Very high strength can be obtained by cold work and aging, giving strengths at or above 220 ksi (5962). In this study, the cold worked material (5962) was directly compared to another material with similar composition and thermal treatment, but without the cold work (5663). While both conditions showed a significantly higher crack growth rate under cathodic protection in 3.5% NaCl than the API 6ACRA variants commonly used in marine environments, the cold worked material had increased environmental fracture toughness compared to the material without cold work despite its higher strength.
Innovative Performance Corrosion Resistance Reinforcing Bars For Extending Service Life Of DOD Structures	Faza, Salem, Michael Stroia, and Homero Castaneda	Performance Corrosion Resistance reinforcing steel bars including continuous galvanized (ASTM A1094) and Low-Carbon Chromium Steel bars(ASTM A1035 CS) have been evaluated for their high corrosion resistance and the mechanism to extend the service life of concrete structures. ASTM A1094 is galvanized rebar with a zinc alloy coating that provides the well-known corrosion protection of zinc and the added benefit of exceptional formability. ASTM A1094 can be bent and fabricated after galvanizing without fear of peeling or flaking. ASTM A1035 CS rebar’s combination of high strength, corrosion resistance and ductility are proven to provide superior blast protection for concrete structures. The high strength can withstand stronger forces, while the ductility dissipates the force across the structural member. In addition, the high strength can be used to efficiently design structures up to 100 Ksi (690 MPa) reducing construction costs and time. Corrosion research findings are discussed in this paper illustrate the efficiency in using these bars to extend the service life of concrete structures depending on the required service life of the DOD structures. In addition to the service life capabilities, supply chain availability should be considered.
Impact Of Materials Deterioration And Corrosion On The U.S. Naval Aviation’s Readiness	Sergei A. Shipilov	The U.S. Navy faces high corrosion costs, surpassing the expenses of most-price ships and weapons systems. Naval aircraft operating in harsh environments are especially susceptible to corrosion, which affects nearly all their components and materials. Corrosion is responsible for over a quarter of the maintenance expenses for naval aviation—every hour of maintenance related to corrosion results in multiple hours of lost availability. Lengthy delays in aircraft maintenance jeopardize the Navy and Marine Corps’ ability to maintain readiness. Corrosion and especially stress corrosion cracking/corrosion fatigue is one of the main (technical) causes why Admiral W.F. Moran, Vice Chief of Naval Operations, told the U.S. House Armed Services Committee that “the Navy’s overall readiness has reached its lowest level in many years” and is declining. The lack of attention to these issues in the U.S. Armed Forces became especially evident when a Marine Corps KC-130T Hercules crashed in 2017 in Mississippi, killing all 16 servicemen on board. The investigation revealed that the growth of a corrosion fatigue crack was “ultimately the root cause of this catastrophic mishap.”

Education, Training, & Fleet Support

Title	Author	Summary
Risk-Based Approach To Corrosion Planning For Army Acquisition Programs	Patrick Taylor	AR 11-42, Army Corrosion Prevention and Control Program, requires that a risk-based approach be used to identify critical components, systems or infrastructure that are susceptible to corrosion. The corrosion degradation of these critical components can lead to the loss of capability or operability, a decrease in safety, an increased need for maintenance, or require special considerations in packaging, storage, and containerization. To aid in this task, a tool is in development to quantify the risk of corrosion occurring on a critical component during deployment. Risk can be calculated by identifying two factors: frequency and consequence. For this specific risk-based approach, frequency will be determined by calculating the corrosion susceptibility of a critical component by using environmental severity, operational hazards, design, preventive maintenance, and storage condition variables. Additionally, the impact of the critical component corroding will serve as the consequence in the calculation of risk by evaluating lifecycle cost and performance. Once frequency and consequence have been quantified the overall risk score can be calculated. If it is determined that the risk is unacceptable, mitigating actions can be taken to reduce risk. The mitigating actions are implemented, and the risk assessment is repeated until acceptable risk is determined. Using the risk-based approach during acquisition to identify critical components most susceptible to corrosion, implementing design improvements and creating maintenance procedures prior to deployment, will reduce the lifecycle cost and increase readiness of the item.
Brush Plating Usage In US Navy And US Marine Corps Aviation Maintenance	Howard Whang, Calvin Chi	Within the US Navy and US Marine Corps aviation maintenance program, brush plating has historically been a depot repair process. However, the process simplicity, the low cost of equipment, and the ease of operation has led NAVAIR to expand the usage of brush plating beyond the depot and out to squadron maintainers worldwide. The usage of brush plating repair methods for performing maintenance directly on aircraft has greatly increased in recent years, thereby increasing military readiness by enabling faster repair turnaround times at a significantly reduced cost. Brush plating is now routinely used by fleet maintainers on F/A-18, H-1, V-22, and F-35 aircraft platforms. This paper explores how brush plating usage developed throughout the US Navy and US Marine Corps, shows some common aircraft repairs that can be done on-site without needing to take an aircraft out of service for repairs, and outlines the future objectives of brush plating within the naval aviation maintenance programs.
Corrosion Prevention Action Team And The AH-64 Apache	Rodney Bishop, Johnothan Blanshan	The Apache Corrosion Prevention Action Team (CPAT) works directly with the units in the US Army that operate and maintain the AH-64 Apache to spot check aircraft for corrosion, field questions from maintenance technicians about corrosion and share common corrosion problems from across the Apache fleet. The Apache CPAT is composed of various government and contractor representatives and works to identify and mitigate corrosion issues. The CPAT strives to reduce the burden on the maintainer while upholding effective corrosion prevention techniques. Focus on units in highly corrosive environments is critical while maintaining cognizance of the entire fleet. Examples can be shown where CPAT assistance resulted in corrosion reduction. The CPAT focuses on design improvements, process improvements and repair development. A corrosion video series was developed that demonstrates proper corrosion checks and corrosion repairs. The video series shows promise as an educational tool for the maintainer. This project is presented to encourage other platforms to pursue similar tools.
Green Non-Drip Mobile Technology For Fast On-Aircraft Spot Anodize And Plating Repair	Siva Palani, Vinod Upadhyay, Keith Legg, Julio Mendez, Alan Rose	Electrochemical brush plating and anodizing is traditionally a messy process, where chemical drips and runs must be contained and channeled to prevent contamination. An OSHA-compliant technology that is portable, non-drip, and well-controlled is now being deployed for repair of DoD weapon systems around the world. The repair process is clean, and fast enough to be done in-place between missions. This electrochemical closed loop technology performs the complete repair – corrosion removal, etching and rinsing in addition to anodizing and electroplating. Presented and discussed in this paper are equipment design and methodologies for repairing electroplates and anodize layers, including such applications as anodizing aircraft floors, static ports and leading-edge erosion shields, and electrolytically stripping and replating corroded fastener heads on aircraft outer mold lines.

Paints & Coatings

Title	Author	Summary
Lightweight Sol-Gel Coating to Mitigate Galvanic Corrosion	Adam Goff, Charles Sprinkle, Ben Pinkston, Grace Le, Ariel Farelas	Galvanic corrosion on aircraft around mechanical fasteners represents a significant portion of total platform maintenance costs and contributes towards reduced operational readiness. Historical approaches to controlling galvanic corrosion involve protecting the anode (e.g. usually the aluminum airframe), but minimal efforts have been made at limiting the galvanic contribution at the cathode. There is a need to improve the galvanic corrosion control tool set across these platforms, and technologies that aid in controlling the available cathodic current density are a new approach. Luna Labs is developing a sol-gel based coating to mitigate galvanic corrosion around fasteners and other dissimilar materials by providing excellent physical and electrical barrier protection to corrosive environments. This sol-gel coating results in a highly cross-linked inorganic/polymer hybrid  film with excellent impact resistance,flexibility, and toughness. It is also inherently chrome-free and non-hazardous. The coating is designed for drop-in fastener application and easy integration with common aircraft components. Corrosion tests have indicated a reduction in observed galvanic corrosion by 2-3 times less compared to that of bare fasteners. This reduction in corrosion will directly translate to cost savings through decreased maintenance of aircraft components and improved operational readiness. A technology development status update will be provided.
Performance Characterization Of Cold Spray For Patch Repair Of Corroded Assets	Joshua P. James	The ability to repair corroded assets in-field or at least prior to full-scale teardown (without decommissioning) ultimately improves productivity, readiness, and reliability. This research seeks to understand the applicability of cold spray to in-field repair of damaged assets, specifically those structures that have suffered deleterious corrosion. Patch repair via relatively low pressure, portable cold spray presents an opportunity to avoid expensive tear down and rehabilitation. However, the differing metallic compositions of cold spray powders and the formation of discontinuous interfaces at the edges of the applied patch may serve to simply change the corrosion mechanism affecting the asset. This work details the characterization of aluminum cold spray patches applied on structural substrates for corrosion resistance, adverse galvanic interactions, and the nature of the bond at the diffuse edges of repair patch borders.
Development Of Water Dispersible CARC With Antimicrobial Properties	Dawn M. Crawford, John A. Escarsega	US Army coatings provide essential protection to Army assets in numerous ways including camouflage, corrosion resistance and chemical agent resistance. Although it has been known since WWII that military equipment is susceptible to microbial attack and deterioration, Army chemical agent resistant coatings (CARCs) do not have requirements for microbial resistance. To address this need, US Army Combat Capabilities Development Command (CCDC), Army Research Laboratory (ARL) initiated a program to assess the microbial resistance of water dispersible CARC and the use of low concentrations of commercial biocides to minimize problems with mold, algae and mildew growth on CARC. This report summarizes the findings of this program and the new requirement for fungal resistance of the water dispersible CARC recently published in MIL-DTL-64159 & MIL-DTL-53039.
100 Year Duplex Zinc Coatings For Seawater Environments	Martin Gagné, Bernardo Duran, Kevin Irving	Thermal spray zinc-alloy coatings have proven to be very robust. Results from 11 years of exposure testing of a zinc 15% aluminum alloy coating at Helgoland Island in the North Sea, including atmospheric exposure, in the splash zone, in the tidal zone and fully immersed, shows coating thickness loss measuring <1um/year in all exposure conditions. Along with excellent corrosion protection, results from impact testing, and both wet and dry abrasion testing, show that the Zn-15% Al alloy coatings also have excellent impact, shock and abrasion resistance. Thermal spray Zn-15%Al alloy coatings offer both barrier protection and cathodic protection to steel. Thermal spray zinc coatings can be applied in the factory or in the field and are not limited by any size constraints. A paint top coat has been shown to extend the life of zinc coatings in severe environments by 50% indicating that a 100 year life is possible with two maintenance paint cycles.
Durable, Hydrophobic Surface Treatment For Enhanced Corrosion Protection Of Landing Gear	Rebecca Martin, Adam Goff, Ben Pinkston, Zak Bear	Under operational conditions, landing gear are subject to numerous damage modes including abrasion/impact damage due to foreign object debris (FOD), rain, sand and dust erosion, runway debris, mechanical abrasion, etc. which remove the corrosion protective coatings, exposing the underlying bare metal. Additionally, water pooling on plating/painted surfaces, crevices, interfaces and threaded parts can promote corrosion. Ultimately, repairing or replacing landing gear parts due to corrosion is a significant maintenance cost. Luna’s Sol-Gel coating is a thin, easily applied, cost effective, mechanically durable and corrosion resistant coating capable of providing enhanced protection to critical landing gear components. The Sol-Gel coating is a hydrophobic, hybrid polymer-inorganic matrix that can be applied directly to metal, metal plating, or over existing MIL-qualified paint systems with excellent adhesion and stability. Accelerated corrosion and environmental exposure of simulated Baseline plated 300M high strength steel (HSS) threaded parts demonstrated significant improvement in corrosion resistance with the Sol-Gel coating. Subsequent work has been performed to validate improved corrosion protection of landing gear components through extended environmental and accelerated corrosion testing of flat panels, as well as coating adhesion and flexibility testing.
Characterizing Environmental Severity For Naval Air Stations	Steven Kopitzke, Alexander Lilly, Kaylee Canales	Characterizing the risk of corrosion due to environmental severity is critical when attempting to optimize aviation maintenance practices. Previous research has shown that a failure to adjust maintenance efforts based on local environments can have deleterious effects on material condition. In light of that, a research study was conducted to characterize and rank the environmental severity of all Naval air stations where F-18 Super Hornet aircraft are based. This yearlong deployment utilized a combination of aircraftspecific witness coupons along with real-time corrosion sensors to assess the local risk of corrosion. Post-exposure analysis then demonstrated how real-time corrosion sensor data can be compiled with traditional corrosion mass loss data to develop site severity rankings, aiding in future maintenance optimization efforts.
Characterizing The Risks And Benefits Of Covered Structures To Prevent Material Degradation	Kaylee Canales, Steven Kopitzke	Covered structures play an important role in reducing the effects of environmental exposure. They help against the degradation of organic coatings, while also protecting against events such as precipitation (rain, snow, and sleet), hail, or other inclement weather. However, there have been small-scale research efforts that have raised concerns that covered structures may exacerbate corrosion when used for longterm storage. Naval Air Warfare Center – Aircraft Division, in collaboration with Naval Research Lab test facilities, deployed a suite of corrosion monitoring equipment at a test site in Key West. A set of test articles were placed outside under a cover, while a second set were boldly exposed. During the postexposure data analysis, both data sets were used to understand how corrosion propagates under different environmental conditions. This study will demonstrate that the use of covers, while beneficial in some instances, could have unintended consequences as well.

Surface Preparation & Pretreatments

Title	Author	Summary
Aluminum Conversion Coatings For Naval Applications	M. Frichtl, E. Trueman	This study evaluated the use of different conversion coating chemistries as a pretreatment within anticorrosive coating systems used by the US Navy on three representative aluminum alloys. The evaluations included usability assessments within Navy ship maintenance processes, corrosion protection on bare substrates, and compatibility with two different coating systems on power-tool and abrasive-blast cleaned aluminum substrates. Accelerated laboratory corrosion testing and natural marine atmospheric exposures were employed to stress the coating systems. A one-year demonstraMon was also conducted on exterior decking on a cruiser. The results show that trivalent-chromium-process conversion coatings performed the best within a wipe-on, dry-in-place process on all representative surfaces. These coatings were found to be effective even without any mechanical surface preparation and improved coating system performance in all evaluated conditions.
A Study To Quantify Surface Preparation Quality.	Dante Battocchi, Luke Wiering	Up to 80% of coating failures are attributed to improper surface preparation prior to application. To accurately test adhesion and corrosion protection of newly developed coatings on metal, we wanted to understand the effect of several common surface preparation practices on aluminum and steel. After application of the surface preparation method to new metal lab coupons, the change in the metal surface characteristics was measured using pull off adhesion. No coating was applied to the surface, and the change in characteristics was measured by applying pull off adhesion dollies on the treated surface and measuring linear polarization resistance. There was significant variation in results amongst treatment methods. A chart differentiating quantitative results for field and laboratory adhesion practices shows that all treatments are not equivalent. A sonication regimen with a cleaning solution resulted in the best performance amongst the laboratory techniques while more traditional solvent-based preparation methods produced the least performance.
Atmospheric Plasma Coating Removal And Surface Preparation For Enhance Coating Adhesion	Jeffrey Piascik, Glenn Astolfi, Peter Yancey, Levi Snowden, Jason Stimson	For military forces, the need for vessels to be docked for maintenance significantly affects fleet availability and the readiness of that force. There is a significant need for a new tool that will accelerate small scale coating removal and enhance adhesion for coating re-application. Atmospheric Plasma Solutions Inc. has developed a single-person-carriable system that uses non-thermal atmospheric air plasma to rapidly remove organic based coatings without altering the surface profile of underlying substrates and modify the surface properties of the bare metal surface to promote chemical adhesion by increasing surface energy. Presented in this work will be the results of tests evaluating the efficacy of non-thermal atmospheric plasma coating removal (APCR) for military applications. Results from laboratory testing as well as on-site testing will be presented in which coating removal performance on multiple coating systems and substrate configurations commonly found in the military industry were evaluated as well as comparative testing performed between APCR and the widely used needle-gunning removal process.
Improved Procedures For Cleaning Prior To Painting	Morgan Brookens, Lauren Paladino, Andrew Sheetz, Jake Rovner	Cleaning is performed at United States Marine Corps (USMC) Corrosion Repair Facilities (CRFs) as a surface preparation best practice prior to blast/paint operations as required by USMC TM 4750-15/1_. The intent of the cleaning step is to remove debris, oil/greases, and other contaminants from the asset surface whose presence could lead to premature coating failure. Corrosion preventative compounds (CPCs) are routinely applied to USMC assets to mitigate the effects of corrosion. By their nature, CPCs are hydrophobic, greasy, or oily, and are designed to be able to withstand harsh operating environments to provide protection. The resilient nature of CPCs provides an important benefit in corrosion protection but proves challenging to appropriately remove prior to coating to avoid coating defects and/or failure. Reports from the field suggest that complete cleaning of CPCs from painted surfaces remains problematic.
Operational Improvements As A Result Of Abrasive Change	Andrew Sheetz, Lauren Paladino, Tim Widing	The USMC (United States Marine Corps) Corrosion Prevention and Control (CPAC) Program operates Corrosion Repair Facilities (CRFs) to rehabilitate approximately 2,000 military assets (ground vehicles and tactical support equipment) each year. Each CRF can perform full coating operations, part of which includes an abrasive blast booth with reclamation system. In review of CRF operations, it was noted that the extreme amount of waste produced from the abrasive blast process created a significant burden for the local waste management team. As a result of this, CPAC decided to study and ultimately make a change of abrasive at one CRF.
A Novel Non-Chrome Pretreatment For Aerospace Magnesium Alloys	L. Baranowski, D. Velazquez, M. Peppel, J. Feis, T. Scholten, J. Elliott, R. Cook	In this work, we describe a non-chromate conversion coating that is highly effective in preventing corrosion of magnesium-based aerospace alloys. We used computational techniques to identify organic molecules that we expected to be highly effective corrosion inhibitors on aerospace-grade magnesium alloys. Experimental screening confirmed that two of the thiol molecules were highly effective at slowing corrosion on AZ31 Mg alloy. Furthermore, we observed a synergistic effective in the magnitude of corrosion inhibition when the two inhibitors were used simultaneously. We incorporated the selected organic corrosion inhibitors into a thin metal oxide pretreatment layer. This required the design of a novel process, so that we could integrate the inhibitors into the pretreatment layer without interfering with the layer morphology or adhesion.
Corrosion Resistant Boegel As A Non-Hexavalent Chromium Pretreatment	Vivek Kapila, Waynie Schuette	Corrosion protection of aerospace alloys has traditionally relied on the use of hexavalent chromium conversion coatings (CCC). However hexavalent chromium is a carcinogen and is toxic to the environment. Earlier, an organo-silane based adhesion promoter (Boegel† , hereinafter referred to as PreA), qualified to BMS10-128, was developed as an alternate to the hexavalent chromium pretreatments.1 Pre-A was originally designed to enhance bond adhesion to aluminum surfaces and adhesion to subsequent epoxy primers, however provided no sacrificial standalone corrosion resistance to the base substrate. This study details investigating the addition of corrosion inhibitors to Pre-A (to develop corrosion resistant Boegel or CRB) to provide an extra layer of corrosion protection adjacent to the metal surface without compromising paint adhesion.

Technology, Transitions, & Evaluations

Title	Author	Summary
IDEaS Corrosion Detection In Ships Sandbox: Technologies Demonstrated And Next Steps	Shona R. McLaughlin	In the spring of 2022, the Canadian Department of National Defence’s Innovation for Defence Excellence and Security (IDEaS) program held a month-long Sandbox event for the Corrosion Detection in Ships challenge. The challenge to the Innovators was to demonstrate technologies that would detect and assess corrosion behind surface coatings such as paint, insulation, tiles, and seamless decking onboard Royal Canadian Navy (RCN) platforms. The challenge received 19 applications, and nine individual Innovators were invited to attend the Sandbox event. Participating Innovators were given the opportunity to demonstrate their solutions in two modalities: i) under ideal conditions on large test panels representing various aspects of the ship such as hull, decking, and piping, and ii) under real-world conditions on an operational RCN vessel. Department of National Defence and the Canadian Armed Forces (DND/CAF) subject matter experts provided feedback on each solution.
Compliant Push-Button Solutions For Your Corrosion Prevention Control Planning	Alan Rose, Siva Palani, Keith Legg, Julio Mendez	Globally, corrosion costs 3-4% of gross domestic product and the US Navy estimates 40% of corrosion costs can be eliminated by better design. New weapon systems, like most commercial products, are now designed using computational analyses of stress, heat transfer, airflow, etc. 70% of sustainment costs are already locked in by initial design, so clearly the use of upfront computational design tools for corrosion assessment, in common with all the other computational tools, has the potential to deliver huge value by avoiding costly mistakes in design and sustainment. Until recently there were no computational design tools, but in the past few years several have become available. From Small Business Innovation Research (SBIRs) we have developed and implemented predictive corrosion tools, particularly for computational galvanic corrosion assessment. A software tool specifically for MIL-STD-889D compliant corrosion analysis, has been incorporated into a 3D environment enabling corrosion map prediction on complex assemblies in a Product Lifecycle Management framework for wide deployment in line with DoD Digital Transformation Strategy.
Cold Spray For Aircraft Structural Repair Of Corrosion Damage	Sarah E. Galyon Dorman, Justin W. Rausch, and Moriah Ausherman	Cold spray (CS) is currently in use in both civil aviation and military aircraft fleets as a method for repairing obsolete or damaged nonstructural parts. Ongoing researched by the United States Office of Naval Research examines the corrosion and mechanical property equivalency of CS repairs on aluminum alloys for structural repairs on aircraft. Prior testing of CS repaired fatigue coupons with 15-30% blend outs are capable of fatigue life improvement near that of an undamaged coupon at two stress ratios. Testing of CS repaired tensile coupons with 15% blend outs have shown properties near or exceeding 90% of wrought material for two alloy systems. Other material property investigations using this repair process, such as corrosion testing are currently underway. This is important in understanding corrosion development of CS in the highly corrosive environments aircraft experience. These combined results are critical to the future of CS and its use for structural repair of aircraft components.
Machine Learning And Computer Vision Approaches For Corrosion Detection	Hai Nguyen, Shengyi Wang, Rebekah Wilson, Brian Eick, Natalie Becerra-Stasiewicz	This study aims at developing a quick and efficient method to evaluate the corrosion of DoD infrastructure. Hundreds of painted/coated test specimens were scribed and exposed to extreme weathering conditions to accelerate corrosion at the predefined scribe marks, in accordance with ASTM D1654. The process of corrosion detection and surface area measurement is typically characterized by its laboriousness and time-consuming nature, necessitating skilled personnel. This study focuses on developing a computer vision-based approach to automatically measure the surface area of corrosion from an image of a test specimen. The computer-vision and machine learning methods utilized in this study are discussed, such as U-Net convolutional neural networks (CNNs) and semantic segmentation. This approach has produced accurate area measurements when tested on new lab specimens. The tool developed in this initial study will then be further expanded to allow for similar capability on large-scale civil infrastructure.

2019 DoD-Allied Nations Technical Corrosion Conference

Accelerated & Outdoor Exposure Testing

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Corrosion Fundamentals

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Corrosion Inhibitors

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Corrosion Modeling

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Corrosion Monitoring & Assessment

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Corrosion Prevention & Control Strategies

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Corrosion Resistant Metallic Materials

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Corrosion Sensors

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Materials for Facilities & Infrastructure

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Paints & Coatings

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Surface Preparation & Pretreatments

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Technology Transitions and Evaluations

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NACE International 

SSPC Training & Education

DAU's Interactive Catalog (iCatalog)

WBDG (Whole Building Design Guide)

Whole Buiding Design Guide Corrosion Training

Where do I go for questions?

​For inquiries, please contact our front desk at 703-697-3909
 

What are noble metals?

​Noble metals are those metals which are resistant to corrosion and oxidation. 

 

What is corrosion?

​Although, the word "corrosion" is most often associated with "rust" and the oxidation of other metals, the Congressional definition of corrosion is, "the deterioration of a material or its properties due to a reaction of that material with its chemical environment" and can be found in 10 U.S.C. § 2228. It is inclusive of the deterioration of all materials, which can be caused through sun exposure, mold and mildew, wind, and other environmental elements.

 

Where can I find corrosion studies?

​Each of these studies have been cataloged on this website. To access them, please follow the link here

 

What does the Corrosion Policy and Oversite Office do?

The Corrosion Policy and Oversight office sponsors and provides training across the DoD weapon system and facilities spectrum. Training and certification opportunities can be found here:

 

1. Defense Acquisition University

 

2. NACE International (The Corrosion Society)

 

3. SSPC (The Society for Protective Coatings)

 

4. Whole Building Design Guide (WBDG)

 

5. CLM 038 Corrosion Prevention and Control Overview

 

Where can I find Facilities Training?

​Facilities training can be completed through the Whole Building Design Guide (WBDG) CPC-source.

The CPC Source contains a broad spectrum of CPC content related to the life cycle of facilities, as well as facilities-related training. Topics include:Coating Fundamentals (1PDH)Corrosion Fundamentals (1PDH)Cathodic Protection Basics (1PDH)Corrosion Prevention and Control of Utilities and Buried Structures (1PDH)Corrosion Prevention of Waterfront and Coastal Structures (1PDH)Coating Selection, Types, Performance, and the Environment (1PDH) - (In development)Coating Application, Quality Control, and Safety (1PDH) – (In development)CPC Facilities Life Cycle (1PDH) – (In development)

 

 

What does the CPC Director do?

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The Director of the Corrosion Policy and Oversight Office (CPO) has partnered with the National Institute of Building Sciences (NIBS) to host the Corrosion Prevention and Control (CPC) Source section on the Whole Building Design Guide (wbdg.org).

 

The WBDG is a robust gateway to up-to-date information on integrated 'whole building' design techniques and technologies.

The WBDG is the only web-based portal providing government and industry practitioners with one-stop access to up-to-date information on a wide range of building-related guidance, criteria and technology from a 'whole buildings' perspective. Currently organized into four major categories—Design Recommendations, Project Management / Operations & Maintenance, Federal Facility Criteria and Continuing Education—at the heart of the WBDG are Resource Pages, reductive summaries on particular topics.

 

The WBDG.org portal houses and maintains a large number of corrosion-related criteria and CPC-related resources. The WBDG is the "go to" location for the government and private sector, and serves as the host for facilities criteria, standards and guidance.

TheCPC Source is intended to help planners, facility managers, sustainers, architects, engineers, and constructors manage problems and make informed decisions to correct and address CPC requirements in new construction and existing facilities. These facilities professionals act to correct deficiencies before corrosion causes failure and downtime and increases sustainment costs. Resource and Knowledge Page topics include:Corrosion Prevention and Control Source OverviewTrainingBest Practices Identified During the Facilities and Infrastructure Corrosion Evaluation StudyEnvironmental Severity ClassificationThe Importance of Including Corrosion in the Planning ProcessAcquisition IssuesSustainment, Restoration, Modernization (SRM), Operations and Maintenance (O&M)CriteriaDesign and Construction IssuesCompetenciesTechnology Transitions into CriteriaCorrosion Science Cathodic ProtectionPaint and Coatings Petroleum, Oils, and Lubricants (POL) Storage Distribution SystemUtilities and Buried StructuresPavementsFencingDoorsWaterfront and Coastal StructuresPiers and Wharves (New)Aviation Facilities (New)

 

 

 

Does the military have their own CPC?

Each Military Department has their own, individual Corrosion Control and Prevention Executive (CCPE). Their names are listed below:

Air Force: Walter Juzukonis

Army: Eric Linderman

Navy​: Edward Lemieux

ASTM International

International Organization for Standardization

National Nanotechnology Initative

Office of the Assistant Secretary of Defense for Sustainment

SERDP-ESTCP

The Electrochemical Society

U.S. Department of Defense

Whole Building Design Guide

The Association of Metals Protection and Performance (AMPP)