Mobile Laser & Coatings

Coatings/Corrosion Prevention

Corrosion is a critical and pervasive issue affecting all fielded artillery, direct-fire and mortar systems that leads to severe pitting and stress corrosion cracking. Left unaddressed, these degradation mechanisms affect the structural integrity, safety, and operational readiness of mission-critical systems such as cannon tubes.

The Laser & Coatings Lab (LCL) at DEVCOM AC Benet Laboratories has developed a novel two-step solution. The process utilizes pulsed fiber laser ablation to precisely and effectively remove existing surface corrosion without damaging the underlying substrate, followed by the application of an air-cured ceramic-polymer coating to prevent future corrosion and environmental degradation.

The combination of these processes is not novel; however, the team developed state-of-the-art equipment kits to complete the process at scale, on a fully mobile platform. Typically, these processes are completed in manufacturing environments with permanent large spray booths and laser safety enclosures. All the necessary equipment for this particular process is portable and packed into two rolling tool storage gang boxes, easily transported to even remote locations. This innovative mobile process has been proven on the OUSD Corrosion Prevention and Control sponsored Howitzer Muzzle End Field Retrofit – successfully completing retrofits at numerous locations worldwide.

Large caliber cannon tubes suffer from stress corrosion cracking on the muzzle end and is the primary cause of condemned cannons, with each replacement representing a significant cost. Prior to the development of LCL’s process, corrosion has historically led to the condemnation of cannon tubes. The field retrofit alone has provided significant long-term cost savings to the DoW. Additional benefits include reduced future maintenance and time savings for preventative maintenance checks, and no corrosion remediation is necessary post coating application. Implementing this advanced mobile corrosion remediation strategy significantly extends the operational lifespan, lowers long-term lifecycle costs, minimizes equipment downtime and most importantly, directly mitigates the risk of potential catastrophic failure due to stress corrosion cracking and pitting. Employing the mobile retrofit kits eliminates the need to ship equipment to a central facility such as a Depot or Arsenal, significantly reducing transit times, simplifying logistics and reducing overall corrosion protection implementation costs.

This process is tailorable to several applications for the Army and other DOW branches. With equipment procurement and proper personnel training, this process is easily transferable and has potential to be a DLA or field level activity. This process can be used on any land-, sea- or air-based system where maximum corrosion protection is required, and logistical challenges are typically faced. The combined technology of pulsed fiber laser ablation and ceramic polymer coating application in a mobile field retrofit has reached the highest TRL. The system has been fully proven through mission success, demonstrating complete operational reliability, safety, and effectiveness in real-world operational environments.