Page 210 - Challenges in Corrosion Costs Causes Consequences and Control(2015)

188 CORROSION CAUSES

Piping or plumbing systems made of copper alloys are susceptible to
erosion-corrosion in unfavorable fluid flow conditions. Erosion–corrosion can
occur when erosive action of the flowing stream removes the protective copper oxide
film from the metal surface, and thus exposing the bare metal surface to a corrosive
environment (44).

3.31 CORROSION PROBLEMS IN THE US DEPT. OF DEFENSE

The ability of the US Department of Defense (DOD) to respond rapidly and effec-
tively to national security and foreign policy commitments can be adversely affected
by equipment-related failures. Using available resources, minimization of downtime
and maximization battle readiness must be accomplished through the useful opera-
tional lifetime of the equipment. If this is done effectively, equipment can be deployed
in a timely and responsive manner and maintained in the field with a minimum of
downtime.
Corrosion of military equipment and facilities is a significant and ongoing prob-
lem. Large amounts of costs are incurred to protect the assets from corrosion, affect-
ing procurement, maintenance, and operations. The effect of corrosion on various
types of equipment is a problem that is becoming more prominent as the acquisi-
tion of new equipment slows down and more emphasis is placed on total care and
operation of the current system. As the intention to operate aging aircraft, ships, land
combat vehicles, and submarines continues into the twenty-first century, the poten-
tially detrimental effects of corrosion on the cost of ownership, safety, and readiness
must be fully appreciated. The effect of corrosion of the DOD equipment will con-
tinue to get worse unless and until new technologies can be used to reduce the cost
of ownership. The total annual cost of corrosion to the DOD is approximately $20
billion for systems and infrastructure (45).

3.31.1 Weapon Systems
The available data from the services indicate that corrosion in weapons systems is
the primary cost driver in life-cycle costs (46). Quantifying corrosion is difficult as
neither the mechanisms nor the methodologies exist to quantify accurately. Analy-
sis of field data reveals instances where questionable materials selection early in the
acquisition process has led to enormous unanticipated increases in life-cycle costs
because of corrosion (J Argento, US Army TACOM-ARDEC, Picatinny Arsenal,
NJ, Personal Communication, 1999). In view of force reduction and a reduction in
budgets, consideration must be given to the selection of advanced materials, pro-
cesses, and designs that will require less manpower for corrosion inspection and
maintenance.
The following discussion concerns specific information on corrosion and related
costs incurred by the Army, the Air Force, the Navy, and the Marine Corps. It should
be noted that the corrosion costs of selected components in these services do not add
up to the $20 billion quoted above. It only serves to demonstrate how corrosion can
significantly affect the equipment and facilities of the armed services.