Case Study 1: High-Mobility Multipurpose Wheeled Vehicle- HMMWV Many American automobile manufacturers have done extensive Research

and Development in building new designs for corrosion-resistant vehicles. However, these designs were not incorporated in the case of Army s high-mobility multipurpose-wheeled vehicle !HMM"#$. %he HMM"# is a light, highly mobile, diesel-powered, four-wheel-drive vehicle e&uipped with automatic transmission. 'xtensive corrosion problems of HMM"# have been reported because of poor design and improper choice of materials. %he HMM"# was first used during the (ulf "ar in )**+-*).. ,ecause of its success, the HMM"# has been an important wheeled vehicle for the Modern Military -orces. However, severe corrosion problems have been detected with some parts of HMM"# !-igure )$. -or example, the frame of this vehicle is made of ordinary, non-galvani.ed, )+)+ carbon steel without any corrosion protection. Another flaw in the body design of this vehicle is that holes were made on the sides and not at the bottom, which exhibited extensive corrosion. %he vehicle was designed to go through )./m deep waters, but lac0 of proper water draining mechanism exposed a serious flaw in the design.

Figure 1: Frame Rail on HMMWV Most of the corrosion problems in this vehicle could be eliminated by using galvani.ed steel or corrosion resistant coatings. )+)+-carbon steel was used in many parts of the vehicle such as springs, tie-downs and 1ift points in addition to the chassis. %he vehicle was secured with bolts at various places to enhance the strength-to-weight ratio except that the bolt locations turned out to be a favored spot for corrosion. A few problems could be prevented by using polymers and substitute metals. (alvanic or dissimilar corrosion occurs because of the variety of metals used on this vehicle. An additional wea0ness in the HMM"# design and specification is the use of non-standard coating systems such as spray paintings, which results in incomplete

painting of some parts. %his problem of corrosion can be avoided by using the electrodeposition techni&ue. Recommendations for Corrosion re!ention on HMMWV All future programs and designs for wheeled vehicles must use the latest corrosion resistant techni&ues. -unds must be allocated for corrosion-concerned maintenance and repairs. 'ven after 0nowing the degree of corrosion in HMM"#, the conse&uences associated with corrosion were overloo0ed. %hese facts must not be ignored. %AA23M !%an0 Automotive and Armaments 2ommand$ 4cience and %echnology 3ffice put together the %AA23M 252 !2orrosion 5revention and 2ontrol$ Ac&uisition document !dated 4eptember )6, )**7$ for HMM"#s. %his document stated the following8 Corrosion Control The vehicle shall be capable of operating for a desired 20-year service life with a 15-year minimum which can include varying or e!tended periods in corrosive environments involving one or more of the following" high humidity salt spray road deicing agents gravel impingement atmospheric contamination and temperature e!tremes# There shall be no corrosion past $tage 1 or corrosion impairment of fit or function# Corrosion control shall be achieved by a combination of design features materials selection %e#g# composites galvani&ed steel '-coat coil coating( production techni)ues process controls inspection and documentation# The minimum re)uirement is galvani&ing of ferrous components in accordance with the attached *alvani&ing +olicy appropriate pretreatment and '-coat primer# $ubse)uent use of rust proofing materials such as ,il-C--.1.- is not a substitute for any of these minimum re)uirements#/ %hough the recent HMM"#s have been protected by using the methods mentioned, most of the military vehicles had no corrosion protection. 9f the corrosion prevention alternatives were considered in the life cycle cost analysis, ma:or cost-savings with the incorporation of corrosion control measures could be noted. ,y following the recommendations of the 4cience and %echnology 3ffice of %AA23M before ac&uisition, the overall cost of ownership of the HMM"#s and other systems would be significantly reduced. 0eferences" ). HMM"# Army -act -ile - http8;;www.army.mil;fact<files<site;hmmwv =. >.4. Marine 2orps 2orrosion 5rograms
http8;;www.cte-online.org;documentfiles;presentations=++7;R7+7)?=+-@>1A?=+B?=+=++7.pdf

7. %AA23M 252 !2orrosion 5revention and 2ontrol$ Ac&uisition Document dated 4eptember )6, )**7. C. $cience of Technology 1ews, #ol. =, Dovember )**E, HF, >.4. Army Material 2ommand.

/. H. Mindlin, ,.-. (ilp, 1.4. 'lliot, and M. 2hamberlain, 2orrosion in D3D 4ystems8 2ata Collection and 3nalysis %+hase 4( M9A2 Report B, Metals 9nformation Analysis 2enter, August )**/. 6. @. Argento, >.4. Army %A23M G ARD'2, 5icatinny Arsenal, D@, 5ersonal 2ommunication, )***. E. Audit Report on HHigh-Mobility Multipurpose "heeled #ehiclesI 3ffice of the 9nspector (eneral, >.4. Department of Defense, )**7. B. (A3 Report on Army Medium %ruc0s 9nformation on Delivery Delays and 2orrosion 5roblems, @anuary )***, (A3;D49AD G **;=;6