Page 213 - Challenges in Corrosion Costs Causes Consequences and Control(2015)

CORROSION PROBLEMS IN THE US DEPT. OF DEFENSE 191

TABLE 3.16 Number and Percentage of Corrosion-Affected Parts in HMMWV
Vehicles
Vehicle Parts Number of Vehicles Affected Percent of Vehicles Affected
Engine Compartment
Heads 49 18
Injectors 53 19
Engine mounts 78 28
Valve covers 87 32
Radiator assembly 131 48
Suspension and Steering
Idler arms 48 17
Control arms 78 28
Rie rods 124 45
Axle housings 161 59
Springs 205 75
Body
Fenders 72 26
Bumpers 105 35
Door frames 115 42
Beds 120 44
Tie downs/lift points 209 76
Underbody
Metal brake lines 35 13
Air tanks 40 15
Drive shafts 105 38
Fuel lines 106 39
Universal joints 135 49
Other
Welded seams 73 27
Fuel tank assemblies 135 49
Nuts, bolts, fasteners 177 64
Frame 187 68

camouflage protection as the paint was available in different colors. The protection by
the CARC paint system was not complete as shown by the data given in Table 3.17.
The CARC paint system hardens after application to an extremely inelastic
product. The metals to which CARC was applied were much more elastic and also
expanded as well as contracted rapidly following environmental conditions. The net
result is the CARC paint and is disbonded from the metal and falls off and leads to
corrosion.
Another weakness of CARC paint is that it is difficult to apply, and field repair
of the coating is difficult. CARC paint contains a high level of volatile organic com-
pounds (VOCs). Strict environmental regulations allow only 0.9 L (1 quart) per day
per area to be used to reduce the level of VOC emissions.