Department of Defense Corrosion Program

Abstract

The Department of Defense (DoD) initiated the Corrosion Program in 2003 in response to 10 U.S.C. 2228, requiring the Secretary of Defense to accomplish a number of actions including the implementation of a corrosion prevention/mitigation strategic plan for DoD equipment and infrastructure. The DoD Corrosion Prevention and Control Strategy was revised and signed in January 2021. Corrosion continues to be a significant contributor to maintenance costs for DoD equipment and facilities. The average annual cost of corrosion by Service and Major Weapon System Platform between 2004 and 2020 was greater than $16 billion, and between 16% and 25% of all maintenance costs are attributable to corrosion, depending on the type of system. GAO reports 18-678 and 21-101SP analyzed the DoD aviation weapon system segment where corrosion was specifically attributed to the reduced reliability and maintainability of 33% of the systems. Four of the systems were noted in both reports. Additionally, GAO-20-296, Defense Nuclear Enterprise Faces Sustainment Challenges, the Air Force attributes corrosion as a degrading factor on at least 3 weapon systems. In GAO-22-105032, the Navy allocates a 6% minimum growth factor for corrosion repairs in its annual shipyard work estimates, resulting in part due to deferred corrosion maintenance. Corrosion remains a direct contributor to reduced system availability. The overall strategic goal of the DoD Corrosion Program is to demonstrate the ability to improve military readiness through the implementation of targeted and effective material and nonmaterial solutions that reduce the corrosion impacts on availability and affordability of DoD weapon systems and infrastructure. This goal can be achieved by focusing RDT&E efforts into two categories: Research Studies and Technology Development and Implementation. Technology development and implementation includes demonstrating and validating mature technologies and advanced research on technologies aimed at reducing cost and increasing availability of DoD weapon systems and facilities. Demonstration/validation projects are specific corrosion prevention/mitigation efforts funded by the CPO with the objective of developing, testing, qualifying, and implementing new technologies. A number of low-risk, high-payoff technologies promise to vastly improve the service life, significantly reduce the maintenance costs, and improve the availability and safety of weapon systems and facilities essential to maintain support for the warfighter. A total of 85 projects have been completed including a follow-on assessment of their return-on-investment estimates. The overall return on investment as estimated by the Military Departments is approximately 17:1. Advanced research includes Test and Evaluation projects, research studies, and research performed by academic institutions to include the Armed Forces’ Academies. The primary objectives are: (1) generate products that contribute to the scientific understanding of material degradation and protection mechanisms, (2) explore the feasibility of technologies or processes for future demonstration/implementation projects, (3) generate knowledge products that contribute to ability to make data-driven decisions to prioritize corrosion prevention investments. Research areas include: • Improved and validated data analytics and predictive modeling • Accelerated corrosion test method development • Improved surface treatments and coatings • New materials and materials processing techniques

Document Details

• Document Type: R2 Budgetary Justification
• Publication Date: Oct 01, 2024
• Source ID: 0604016D8Z_4_0400_PB_2024
• Change Summary Explanation: No funding change for FY 2024.
• Service Agency Name: Office of the Secretary Of Defense

Entities

Organizations

• Office of the Secretary of Defense

Tags

Communities of Interest

• Ground and Sea Platforms

DTIC Thesaurus Topics

• Additive Manufacturing
• Air Force
• Corrosion
• Corrosion Inhibition
• Cost Reductions
• Data Analysis
• Department Of Defense
• Fighter Aircraft
• Growth Factors
• Maintenance
• Maintenance Costs
• Material Degradation Processes
• Materials
• Materials Processing
• Predictive Modeling
• Test And Evaluation
• Test Methods

Readers

• Defense Acquisition Program Management
• Life Cycle Cost Analysis
• Materials Science and Engineering.