Thermoplastic Powder Coating Hits the Beach

By Fred Allen

A recently developed coating repair method has been accepted by the United States Marine Corps as a means of saving millions of dollars in remanufacturing costs. The Light Armored Vehicle (LAV) is an eight-wheeled amphibious reconnaissance vehicle used by the United States Marine Corps for a variety of functions, including security, command and control, reconnaissance, and assault (Figure 1). The LAV operates on land and in water, carries communications equipment, and provides a weapons platform.

Considering the demanding operating conditions of LAVs, these vehicles require coating materials that can withstand humidity, temperature, impact, wear, and corrosion. The drive shaft, for example, is coated with Nylon 11, a material known for its toughness and weatherability.

In 2004, 80% of the LAV drive shafts were being scrapped at the Marines’ Albany Maintenance Center because of the Nylon 11 coating disbonding from the metal. A team from Rochester Institute of Technology (RIT) led by Prof. Michael Haselkorn developed a re-manufacturing process using a novel thermoplastic powder to repair the damaged Nylon 11 coating,¹ enabling the drive shafts to be reused and saving the Marines $1.5 million each year.