US Army Research Laboratory - Apps.dtic.mil

US Army Research LaboratoryWeapons and Materials Research DirectorateCoatings Developments for VehiclesWay ForwardDOD CARC Commodity ManagerCoatings TeamPhone: 410-306-0693Email: john.a.escarse@us.army.milUNCLASSIFIED: Approved for public release; distribution unlimited.Courtesy of U.S DoDJohn A. Escarsega

Form ApprovedOMB No. 0704-0188Report Documentation PagePublic reporting burden for the collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, gathering andmaintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information,including suggestions for reducing this burden, to Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, ArlingtonVA 22202-4302. Respondents should be aware that notwithstanding any other provision of law, no person shall be subject to a penalty for failing to comply with a collection of information if itdoes not display a currently valid OMB control number.1. REPORT DATE3. DATES COVERED2. REPORT TYPEJUN 201000-00-2010 to 00-00-20104. TITLE AND SUBTITLE5a. CONTRACT NUMBERCoatings Developments for Vehicles Way Forward5b. GRANT NUMBER5c. PROGRAM ELEMENT NUMBER6. AUTHOR(S)5d. PROJECT NUMBER5e. TASK NUMBER5f. WORK UNIT NUMBER7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES)U. S. Army Research Laboratory,Weapons and Materials ResearchDirectorate,Aberdeen Proving Ground,MD,210059. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES)8. PERFORMING ORGANIZATIONREPORT NUMBER10. SPONSOR/MONITOR’S ACRONYM(S)11. SPONSOR/MONITOR’S REPORTNUMBER(S)12. DISTRIBUTION/AVAILABILITY STATEMENTApproved for public release; distribution unlimited13. SUPPLEMENTARY NOTESDOD Vehicle Workshop, 15-16 June 2010, Grand Rapids, MI. Sponsored by SERDP/ESTCP.14. ABSTRACT15. SUBJECT TERMS16. SECURITY CLASSIFICATION OF:a. REPORTb. ABSTRACTc. THIS PAGEunclassifiedunclassifiedunclassified17. LIMITATION OFABSTRACT18. NUMBEROF PAGESSame asReport (SAR)2219a. NAME OFRESPONSIBLE PERSONStandard Form 298 (Rev. 8-98)Prescribed by ANSI Std Z39-18

Outline Who we are & What we do Prior History and Evolution of CARC Considerations for the future Coatings Systems for Land Vehicles GAPS to address and Considerations forCoatings AdvancementCourtesy of U.S. ArmyCourtesy of U.S. DoDUNCLASSIFIED: Approved for public release; distribution unlimited.

Who we are . ARL is the Lead DOD R&D Activity for CARC¾ Innovative formulations approaches¾ New raw materials selections¾ Advanced characterization Maintains Ownership for all key specificationsregarding pretreatments, primers and topcoats for alltactical and related support equipment and munitioncoatings. Elements above assist to implement and transitionproductsUNCLASSIFIED: Approved for public release; distribution unlimited.

Guiding Principles for Coating IFIED: Approved for public release; distribution unlimited.

Good Intent Smithsonian Magazine , April 1999UNCLASSIFIED: Approved for public release; distribution unlimited.

New Paradigm in Coatings Recent Coatings represent superior durability,environmental compliance Stereotypes associated with Emulsions, Water Based orHexavalent Chromium Free chemistries no longer hold true. Current efforts establishes solid foundation for presentand future survivability enhancements and multifunctionalcapabilities Services are moving rapidly to eliminate standard coatingsused and are implementing a new generation of coatingtechnology throughout DODUNCLASSIFIED: Approved for public release; distribution unlimited.

Considerations for the Future 20-25 years ago Army- Marine Corps Coating systemswell defined. DoD had sufficient outdoor exposure history andsubmissions were similar to one another. It was appropriate to use neutral salt fog for QCvalidation. Since we had field history and correlation were inhand, confidence was high if lab test were satisfactoryoutdoor life cycle would be predictable . Today this is no longer the caseUNCLASSIFIED: Approved for public release; distribution unlimited.

Considerations for the Future Today this is no longer the case . We have numerous mandates, existing laws andguidelines that require novel and unique chemistries Multiple substrates to contend with and a largerselection of topcoats, primers and pretreatments thatwhen evaluated as a “system” mitigate and preventcorrosion and degradation in different ways. HENCE AS A COMMUNITY WE CANNOT DO AS WEARE DOINGUNCLASSIFIED: Approved for public release; distribution unlimited.

Considerations for the Future HENCE AS A COMMUNITY WE CANNOT DO AS WEARE DOING: MAKE ASSUMPTIONS THAT ALL CORROSIONINHIBITORS WILL RESPOND OR ACT SIMILAR IN ANYACCELERATED CHAMBER EVALUATION X HOURS IN TESTING PROVIDES CONFIDENCE SERVICES RESPONSIBLE FOR VALIDATION NOTKNOWING THE COMPOSITON OF MATERIALS USED THINKING THAT AN “ADVANCE ACCELERATEDPROTOCOL” WILL BE THE ANSWER FOR QUICKER ORMORE EXPEDIENT DATAUNCLASSIFIED: Approved for public release; distribution unlimited.

Considerations for the Future THINKING THAT AN “ADVANCE ACCELERATEDPROTOCOL” WILL BE THE ANSWER FOR QUICKER ORMORE EXPEDIENT DATA . UNLESS WE KNOW THE CHEMISTRIES AND CANCONFIRM SIMILAR DEGRADATION MECHANISMS INOUTDOOR EXPOSURE AND CHAMBERS IT IS AFAÇADE TO BELIEVE X HOURS IS PREDECTIVE OF XTIME OUTDOORS.UNCLASSIFIED: Approved for public release; distribution unlimited.

36 YEAR TIME LINE OF CARCFeb 1st 1974Publication ofMIL-C-46168November 13th1984 Eliminate:Light Green,Forest Green,Olive Drab, EarthRed, Earth Brownand Desert SandColors.May 1st 1974Publication ofMIL-E-52798Feb 28th 1983:Move towardthree colorpattern to betteralign with NATOAlliesApril 16th 1984Publication ofMIL-C-53039 OneComponentCARCOctober1985Inclusion of383 Green (#34094)Co-ExistCARC andNON-CARC74July 1st 1987Cancellation ofMIL-E-52798838485JUNE 2ND 1988INCOMING 4 STARAMC GENERAL ANDRETIRING 4 STARGENERAL JOINTLYSIGN MEMODECLARINGPOLYURENTHANECOATINGS WILL BETHE COATINGSUSED ON ALLTACTICAL ANDRELATED SUPPORTEQUIPMENT87UNCLASSIFIED: Approved for public release; distribution unlimited.88MID 90’s through early2000sMIL-C-46168 & MIL-C-53039EQUAL IN USAGE ANDARE USED BY ALLSERVICES WITH ARMYAND MARINE CORPS ASTHE PREDOMINANTUSERS.OCT 2005:MIL-C-46168 is Canceledand Replaced with MILDTL-64159 WD-CARCIN 1988 GSA PUTS OUT BIDFOR 230,000 GALLONS .TODAY WE MANAGE 2MILLION GALLONS WITHMIL-DTL -53039 AND 641592010

Materials Technology Success StoryDetails: Water Dispersible CARCTACOMUSERCommunityrequestLOW VOCTOPCOATSERDPFunds LOWVOCEFFORTARLINTIATESLOW VOCTOPCOATEFFORTINITIALfundingprovided forone yearSERDPBAYERDevelopsInitial RESINSystemNON-CARCARL CProvidesfunds forfurtherresearchARLPATENTJUNE 1997WD CARCESTCPDEM/VALARL LEADS TRISERVICE INTOEXPERIMENTALPRODUCTSAVAILABILITYSERDP FundsDEGRADATIONEFFORTWD CARC iscurrently beingused by all ofMarine Corpsand Armyelements andcomprisesapproximately20% of theMarketMARINE CORPSSends COMMANDLEVEL MESSAGEIMPLEMENT WDCARCDetailedSpecificationReleased withStock NumbersSupportsand QualifiedPolymericVendorsFlattening Agentin TOPCOATS93 94 95 96 97 98 99 00 01 02UNCLASSIFIED: Approved for public release; distribution unlimited.03

Current Volume of Coatings Chemical Agent Resistant Coatings (CARC) is mandated byAR-750-1 for all tactical equipment. Every initial submission is fully tested and validated forQualified Listing. Each batch from the initial submission is tested for color,gloss, IR and decontamination resistance. Included in thebatch submission is batch volume. Next slide total volumes* Volume of coatings usage by Army is enormous: Severalmillion gallons costing several hundred of millions of dollarsannually will be reduce as developments are implementedand durability is improved.UNCLASSIFIED: Approved for public release; distribution unlimited.

Average VOC (lb/gal)CARC Topcoat*January to May

CARC Batch VolumeMay 2009 – May 2010

Pigments/ExtendersPolymeric beadsArmy willDiscontinue useof Silica basedtopcoats Integrated within Film Polymeric beads– Reduce chalkingeffect– Improve UVresistance– ImproveperformanceDiatomaceous silicaTalcUNCLASSIFIED: Approved for public release; distribution unlimited.

Elimination of Silica FlattenedTopcoats Letter has been issued:Key Points No longer accepting silica basedcoatings November 1st 2010 discontinue batchvalidation Deplete inventories until consumedUNCLASSIFIED: Approved for public release; distribution unlimited.

MIL-DTL-53030 Water Based Epoxy &MIL-DTL- 53022 Solvent Based New type to include Enhanced Corrosion Resistanceand require cyclic corrosion evaluation. 1000Hrs Neutral Salt Fog– ASTM D610 RATING OF 9– ASTM D1654 RATING OF NOT LESS THAN 6 FOR STEEL– ASTM D1654 RATING OF NOT LESS THAN 8 FOR AL. 40 Cycles– ASTM D1654 RATING OF NOT LESS THAN 7 FOR STEEL& AL. Open to novel corrosion inhibitors Allowing vendors to provide exempt solvent packageand provide a universal exempt solvent Similar effort to occur for 53022UNCLASSIFIED: Approved for public release; distribution unlimited.

MIL-DTL-53084 E-CoatMIL-PRF-32348 Powder Coat MIL-DTL-53084 and Powder to includethe color Black. Open to novel corrosion inhibitors Powder Specification to include bothPrimer and Topcoat within samedocument Coordination Date 8/10UNCLASSIFIED: Approved for public release; distribution unlimited.

GAPS AND CONSIDERATIONS The key hurdle is acquiring long term outdoorexposure data for platforms making current andnear future decisions. Confidence that our accelerated screeningprocesses are relevant to long term exposureresults. Ensuring pretreatment and coating processesare followed accurately to enhance corrosionresistance and provide adequateadhesion/compatibility for subsequent coatings.UNCLASSIFIED: Approved for public release; distribution unlimited.

Multiple Phase ApproachPhase I:Phase II:Data, claims and performanceparameters (acceptance based onenvironmental compliance, cost toinclude return on investment andprocess requirements)ARL/TARDEC testing and evaluation of pretreatmentor process using coupon panels to includeaccelerated and cyclic corrosion, EIS, and relatedadhesion type evaluations etc.Phase III: Application ofcomponent parts /panelsPhase IV:Outdoor exposure in corrosive environment ofcomponent parts/panels ( Items would be monitoredfor x years at 6 month intervals)This Phase type process would allow PMs to be aware of what items arecurrently being evaluated and also providing a certain level of confidence toselect or use a particular new process. Baselines will be selected and used asstandards for comparison. In this way new technologies can be evaluated anddata acquired.UNCLASSIFIED: Approved for public release; distribution unlimited.

Increased Options forBalanced ementsEnvironmentalUV & Corrosion ResistanceAffordableMultifunctionalCoating SolutionsFlexibilityAffordabilityNew coatings formulationsMore Survivable and Durable PlatformsUNCLASSIFIED: Approved for public release; distribution unlimited.

mil-c-46168 & mil-c-53039 equal in usage and are used by all services with army and marine corps as the predominant users. oct 2005: mil-c-46168 is canceled and replaced with mil-dtl-64159 wd-carc in 1988 gsa puts out bid for 230,000 gallons .today we manage 2 million gallons with mil-dtl -53039 and 64159