Deputy Director, Office of Corrosion Policy and Oversight Rich Hays Deputy Director, Office of Corrosion Policy and Oversight richard.a.hays18.civ@mail.mil Unclassified – Approved for Public Release

How Many Laws Govern Corrosion? 2nd Law of Thermodynamics “Every process occurring in nature proceeds in the sense in which the sum of the entropies of all bodies taking part in the process is increased. In the limit, i.e. for reversible processes, the sum of the entropies remains unchanged.” (Planck) 10 U.S.C. 2228 “…the deterioration of a material or its properties due to a reaction of that material with its chemical environment.”

Corrosion Examples General and Crevice Corrosion of Steel Alkali-Silica Reaction in Concrete Environmentally Influenced Cracking uV Degradation of Organic Coating System

Impact of Corrosion on Cost

Corrosion Impact on System Availability (FY 12) TMS Corrosion NA days Maintenance NA Days Percent NA days due to corrosion Corrosion cost Maintenance cost Percent Maintenance cost due to corrosion FA-18F 8,568.7 36,593.2 23.4% $ 129,413,318 $ 485,278,472 26.7% MH-60S 7,759.6 32,518.0 23.9% $ 163,673,579 $ 535,001,742 30.6% FA-18E 7,472.9 30,127.5 24.8% $ 111,999,723 $ 389,589,824 28.7% T-45C 7,329.9 24,821.8 29.5% $ 39,051,168 $ 126,111,589 31.0% CH-53E 6,380.5 23,901.5 $ 227,510,653 $ 797,558,870 28.5% MV-22B 4,816.4 25,338.5 19.0% $ 141,592,508 $ 551,438,956 25.7% AV-8B 4,362.0 19,270.5 22.6% $ 99,709,942 $ 405,194,580 24.6% FA-18D 4,347.9 18,543.9 $ 51,921,906 $ 221,779,129 MH-60R 3,957.9 16,768.1 23.6% $ 111,683,003 $ 318,395,707 35.1%

Corrosion Impact on Safety Department of Navy Aviation Corrosion-related Mishaps

DoD Corrosion Organization USD Acquisition, Technology and Logistics ASD, Logistics and Materiel Readiness ASD, Acquisition Dir, International Cooperation ASD, Research and Engineering ASD, Energy Installations and Environment Army Corrosion Executive Director, Corrosion Policy and Oversight Navy Corrosion Executive AF Corrosion Executive WIPTs DoD Corrosion Prevention and Control IPT Policy and Requirements Metrics, Impact and Sustainment Science and Technology Outreach and Communications Facilities Training and Certification Specifications/Standards and Product Qualification IPT member representatives OSD Joint Staff/J-4 Army Navy Air Force Marine Corps Army Corps of Engineers National Aeronautics and Space Administration US Coast Guard Defense Logistics Agency General Services Administration

What We Do Activities Project and Research Sponsorship Policy Development and Implementation Weapon System and Major Facility Program Reviews Workforce Development Corrosion Metrics Collection and Analysis Specifications and Standards Communication and Outreach Project and Research Sponsorship Demonstration/Implementation Projects through Military Departments Technical Corrosion Collaboration

70% of sustainment costs are locked in by initial design Policy Draft DoDI 5000.02 – Operation of the Defense Acquisition System – requires CPC planning for all systems (including MAIS, COTS, and GOTS) throughout the lifecycle “…..planning for and establishing 1) a management structure for CPC, and 2) the technical considerations and requirements in order to implement an effective CPC regime throughout the life cycle of a program.” Planning documented in the Systems Engineering Plan and the Life Cycle Sustainment Plan DoDI 5000.67 - Prevention and Mitigation of Corrosion on DoD Military Equipment and Infrastructure – establishes structure of DoD Corrosion Program and responsibilities DoDD 4151.18 - Maintenance of Military Materiel – requires that corrosion prevention and control programs and preservation techniques be established throughout the system life cycle. 70% of sustainment costs are locked in by initial design

Technology Demonstration/Implementation Projects Objective – Implement mature corrosion control technologies in new and existing weapon systems and facilities Military Department-generated projects to assess products and processes Demonstrate effectiveness in operational systems Update technical and logistics documentation More information available at www.corrdefense.org

Technical Corrosion Collaboration (TCC) Objectives Produce solutions (knowledge, technologies, processes, materials, etc.) that tangibly reduce the impact of corrosion on DoD weapons systems and infrastructure. Produce individuals with education, training and experience, who will form the future core of the corrosion prevention and control technical community within DoD, its support network, and its suppliers.

TCC Technology Investment Categories Assessment of Finish Surface Engineering Performance Prediction Product Support Packaging/Storage Shelf-life Energy Maintenance Models Accelerated Testing Validation Design Tools Mechanical Properties Integrity Galvanic Interaction Degradation Mechanisms Mechanical Coating removal Substrate damage Adhesion Promotion Sacrificial Cleanliness Requirements

New Technology Implementation Challenges Technical Challenges Laboratory Testing Selecting the right test Understanding the inherent inaccuracies and difficulties interpreting results Inability to quantitatively measure and extrapolate outcome of testing Full-Scale Demonstration Testing Cost Integrating with operations and maintenance Limited statistics Performance must be tracked and benefits judged in a short time Inability to quantitatively measure outcome of testing

New Technology Implementation Challenges Administrative Challenges Incentives – contracts do not incentivize the use of new corrosion control technologies Risk Aversion – New technologies are viewed as high risk Qualification of Technology – Existing qualification tests might not apply Specifications and Drawing Modification – Specifications, standards, and drawings must be updated Procurement – Procurement officials resist buying from sole suppliers Supply – Centralized bulk purchasing may extend time in warehouse prior to distribution. Training – New technologies often require training on special application or installation techniques. Resistance to Change – People resist change in the way that they are doing business

Some Final Thoughts Corrosion is rarely just a technical problem Prevent Detect Mitigate Manage Corrosion doesn’t hurt today but it hurts tomorrow Easier to invest in corrective than preventive maintenance Corrosion is often a “people” problem Hard to maintain leadership focus Successful corrosion control requires Awareness and buy-in from leadership Teamwork between subject matter experts, designers, and maintainers – “Corrosion control is not the most important thing we do.” Tools, training, and time for the personnel implementing the processes