Page 331 - Challenges in Corrosion Costs Causes Consequences and Control(2015)

DEFENSE 309

A major portion of the corrosion cost of $2 billion is attributed to Army ground
vehicles such as:

1. Abraham Tank Systems – MI Abrams
2. Bradley Fighting Vehicle Systems
M2 Infantry Fighting Vehicles (IFV)
M3 Cavalry fighting Vehicles (CFV)
Multiple-Launch Rocket System (MLRS)
Command and Control Vehicles (C2V)
Bradley Carrier Systems
Bradley Fire Support Vehicles
Medium Tactical Vehicles (MTV)
1
2 / 2 Ton Cargo Trucks
5 Ton Cargo Trucks
High-Mobility Multipurpose Wheeled Vehicles (HMMWV)
Light Armored Vehicles

In general, very little attention is given to corrosion and corrosion control of army
vehicles. Little has been done to incorporate corrosion protection and control in the
design and manufacture of army vehicles. The significant shortcomings are:

1. Use of 1010 carbon steel without galvanizing or any protective coatings.
2. Presence of many galvanic couples and the use of more than 2800 rivets that
may act as possible locations for corrosion.
3. Use of painting procedures that are not state of the art.
4. Use of paint that provides little corrosion protection, such as the chemical
agent-resistant coatings that deteriorate rapidly in the presence of a corrosive
environment.

Corrosion of HMMWV and other vehicles cost about 2–$2.5 billion/year and cor-
rosion also affected the readiness of the vehicles. Corrosion damage was greater than
65% of the vehicle acquisition cost and the vehicles requiring corrosion repairs were
out of service for about 2–12 months. Vehicles as old as 5 years had to be scrapped
and replaced by new vehicles.
An analysis of the corrosion control deficiencies of the HMMWV indicated that
the corrosion problems in these vehicles are a result of design mistakes. A glaring fault
is that the frame is built of 1010 carbon steel without galvanizing or any other form
of corrosion protection. Holes were drilled into the sides of the frame members and
no holes at the bottom of the frame to allow for drainage. This allowed for stagnation
of the water in the interior of the frame leading to corrosion from inside out. The lack
of drainage on a vehicle designed to be used in water up to 1.5 m (60 in.) deep shows
poor design of the vehicle.