1. Deputy Director, Office of Corrosion Policy and Oversight
Rich Hays
Deputy Director, Office of Corrosion Policy and Oversight
Unclassified – Approved for Public Release

2. 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.”

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

4. Impact of Corrosion on Cost

5. 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%

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

7. 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

8. 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

9. 70% of sustainment costs are locked in by initial design
Policy
Draft DoDI – 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 Prevention and Mitigation of Corrosion on DoD Military Equipment and Infrastructure – establishes structure of DoD Corrosion Program and responsibilities
DoDD 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

10. 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

11. 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.

12. 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

13. 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

14. 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

15. 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