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Article Article An Optimised Optimised Approach Approach of of Protecting Protecting and and Sustaining Sustaining An Large Vehicle Vehicle System System Large Adil Saeed *, Zulfiqar A. Khan and Main H. Nazir Adil Saeed *, Zulfiqar A. Khan and Main H. Nazir Received: 5 October 2015; Accepted: 7 December 2015; Published: date Received: 5 October 2015; Accepted: 7 December 2015; Published: 11 December 2015 Academic Editor: Muge Mukaddes Darwish Academic Editor: Muge Mukaddes Darwish NanoCorr, Energy & Modelling Research Group, Bournemouth University, Dorset BH12 5BB, UK; NanoCorr, Energy & Modelling Research Group, Bournemouth University, Dorset BH12 5BB, UK; zkhan@bournemouth.ac.uk (Z.A.K.); hnazir@bournemouth.ac.uk (M.H.N.) zkhan@bournemouth.ac.uk (Z.A.K.); hnazir@bournemouth.ac.uk (M.H.N.) * Correspondence: asaeed@bournemouth.ac.uk; Tel.: +44-(0)-1202-965732 * Correspondence: asaeed@bournemouth.ac.uk; Tel.: +44-(0)-1202-965732 Abstract: This article is a synopsis of our research and highlights the outcomes and its impact. It Abstract: This article is a synopsis of our research and highlights the outcomes and its impact. was conducted for the development of a sustainable approach to protect and sustain large vehicles It was conducted for the development of a sustainable approach to protect and sustain large vehicles in sheltered environment for their enhanced longevity. In this research, various modes of failures in sheltered environment for their enhanced longevity. In this research, various modes of failures linked directly or indirectly to the structural ageing of large vehicles were identified, measured, linked directly or indirectly to the structural ageing of large vehicles were identified, measured, and analysed. Based upon the research conducted, a frame-work with an objective to prolong the and analysed. Based upon the research conducted, a frame-work with an objective to prolong the structural longevity cost effectively and to retard structural failures has been proposed. structural longevity cost effectively and to retard structural failures has been proposed. Keywords: sustainable; corrosion; large vehicle; paint system Keywords: sustainable; corrosion; large vehicle; paint system 1. Introduction 1. Introduction In this to military military tanks, tanks, one In this article, article, the the term term large large vehicles vehicles refers refers to one such such example example is is shown shown in in Figure 1, 1, and and only only considers considers research research conducted conducted on on such such vehicles. vehicles. These Figure These large large vehicles vehicles are are complex complex objects with a objects with aa wide wide variety varietyof ofinteracting interactingcomponents, components,materials, materials,designs designsand andare aremanufactured manufacturedfor for aspecific specificlife lifespan. span.However, However,during duringand andbeyond beyondtheir theirservice servicelife, life, these these vehicles vehicles start start to to endure endure structural ageing, mainly attributed to materials and component degradation through corrosion and structural ageing, mainly attributed to materials and component degradation through corrosion wear. and wear. Figure 1. Corrosion damage in Russian T 55 IMR recovery vehicle stationed outside the shelter. Figure 1. Corrosion damage in Russian T 55 IMR recovery vehicle stationed outside the shelter. The Tank Museum at Bovington United Kingdom owns a considerable fleet of high-value, large The Tank at Bovington United Kingdom owns a considerable fleet of high-value, vehicles. TheseMuseum large vehicles were exposed to extreme working and operating conditions in large vehicles. These large vehicles were exposed to extreme working and operating conditions battlegrounds during their service life and therefore display structural degradation influenced by Sustainability 2015, 7, page–page; doi:10.3390/su71215825 Sustainability 2015, 7, 16451–16464; doi:10.3390/su71215825 www.mdpi.com/journal/sustainability www.mdpi.com/journal/sustainability Sustainability 2015, 7, 16451–16464 in battlegrounds during their service life and therefore display structural degradation influenced by corrosion and wear. The exact location and duration of their operation is not known and the information is not documented. Corrosion has a strong impact on these high value vehicles and the development of a framework to protect and sustain these high value vehicles against structural degradation is needed. This article represents the synopsis of our wider research, which was designed to understand the prevailing failure mechanisms, measure and monitor the identified issues, establish their cause impact, in an effort to achieve an optimised approach to sustaining and protecting large vehicles sustainably and cost effectively beyond their original design life [1–15]. This is the first evidence-based research carried out in this field and is directly linked to the development of a new sustainable sheltered facility incorporating environmental and corrosion condition monitoring systems, to produce further research and research grants. During the overall project, a five-fold research pattern based on the concept of identifying, measuring, analysing, monitoring and protecting against structural defects was adopted. First, advanced scientific means were utilised for the identification of failures, this was followed by measurement and analysis of failure in materials and paint-systems. Secondly, a framework to monitor the environment and minimise environmental variations (i.e., temperature and relative humidity) was implemented. Third, an in-situ corrosion condition monitoring system has been deployed and useful data are collected. Finally, an empirical model to help design a life expectancy programme and to model materials and paint-system failures for the vehicles stationed in the shelters is proposed. The five-fold research pattern approach helped to initiate restructuring of the storage, operation and maintenance mechanisms for large vehicles considered in our research. In this article, some examples of the corrosion damage analysis, component failures, environmental analysis, the initiation and development of an optimised framework for vehicles protection and the research impact are provided. Vehicles presented in this article are stationed in Bovington, United Kingdom. 2. Research Findings In this research, corrosion damage, un-sustainable environmental conditions, paint system failures and component failures were identified as major structural integrity menaces in the large vehicles. 2.1. Vehicles’ Corrosion Risks of failures due to corrosion are high and pose significant danger to the structural integrity of large vehicles considered in our research. The magnitude of corrosion is different in every vehicle, which could be the result of their operating environment in different terrains and/or the current environmental/operating conditions. The overwhelming phenomenon of corrosion is shown in Figures 1 and 2. Figure 1 is of a Russian T55 IMR that is stationed outside the shelter and is structurally corroding. Figure 2 shows the severity of the corrosion problem in Togg II, a vehicle stationed inside the shelter. The mechanism of structural degradation was dictated by various modes of corrosion working alone and/or together. In this article, damage due to surface corrosion has been reported briefly. Results of other forms of corrosion, i.e., stress corrosion cracking and pitting, are published elsewhere [2,4,5]. 16452 Sustainability 2015, 7, 16451–16464 Sustainability 2015, 7, page–page Figure 2. Corrosion damage to Tog II vehicle stationed inside the shelter. Figure 2. Corrosion damage to Tog II vehicle stationed inside the shelter. Corrosion Damage Evaluation 2.1.1. Corrosion Damage Evaluation Surface corrosion damage was evaluated through the advanced surface analysis techniques of Surface corrosion damage was evaluated through the advanced surface analysis techniques of ultrasonic scanning. Corrosion surface morphology, and surface contaminants were characterised ultrasonic scanning. Corrosion surface morphology, and surface contaminants were characterised by by using a scanning electron microscopy and an energy dispersive X-ray spectroscopy. In the first using a scanning electron microscopy and an energy dispersive X-ray spectroscopy. In the first phase phase of the research, six vehicles the, Russian BTR-60, Centaur A27L, Sherman M4A1, Tank of the research, six vehicles the, Russian BTR-60, Centaur A27L, Sherman M4A1, Tank Destroyer M10, Destroyer M10, Tiger 1 and King Tiger, were considered. Results from BT-R 60 are presented here Tiger 1 and King Tiger, were considered. Results from BT-R 60 are presented here briefly. briefly. Ultrasonic scanning method is a novel technique for measuring the thickness of the metal Ultrasonic scanning method is a novel technique for measuring the thickness of the metal non-intrusively. An ultrasonic scanning system consists of a transducer, pulser receiver, receiver, non-intrusively. An ultrasonic scanning system consists of a transducer, pulser receiver, receiver, transmitter and a display monitor. The system utilises sound waves within the frequency range of 0.1 transmitter and a display monitor. The system utilises sound waves within the frequency range of to 15 MHz rather than radiation. The transducer creates sound waves that travel through the metal 0.1 to 15 MHz rather than radiation. The transducer creates sound waves that travel through the which when these waves strike against a defect or the back wall are then reflected back. The reflected metal which when these waves strike against a defect or the back wall are then reflected back. The sound wave signal is converted into an electrical signal to a display device. In our research, such reflected sound wave signal is converted into an electrical signal to a display device. In our research, information were extrapolated to measure the remaining thickness of the metal component [16,17]. such information were extrapolated to measure the remaining thickness of the metal component Scanning Electron Microscopy (SEM) was used for micro-structural characterisation of the [16,17]. surface and sub-surface defects. To identify surface contaminates on the selected samples, Energy Scanning Electron Microscopy (SEM) was used for micro-structural characterisation of the Dispersive X-ray Spectroscopy (EDS) was performed. Both SEM and EDS are advanced and surface and sub-surface defects. To identify surface contaminates on the selected samples, Energy established techniques utilised for the aforementioned analysis. Dispersive X-ray Spectroscopy (EDS) was performed. Both SEM and EDS are advanced and established techniques utilised 2.1.2. Brone-Transporter BTR 60for the aforementioned analysis. Brone-Transporter BTR 60 Brone-transporter 60 (BTR-60) was manufactured by Gorkovsky Avtomobilny Zavod in the former USSR during 1960–1976. It iswas onemanufactured of the most widely used personnel carriers.Zavod It remained Brone-transporter 60 (BTR-60) by Gorkovsky Avtomobilny in the in production till 1976 [18]. This vehicle was captured during the First Gulf War. This vehicle is former USSR during 1960–1976. It is one of the most widely used personnel carriers. It remained in parked outside the shelter currently and is exposed to an uncontrolled environment. This vehicle is production till 1976 [18]. This vehicle was captured during the First Gulf War. This vehicle is parked severelythe corroding; a sampleand of the compartment cover was collected for corrosion mapping shown outside shelter currently is exposed to an uncontrolled environment. This vehicle is severely in Figure 3 with the corresponding ultrasonic scan. corroding; a sample of the compartment cover was collected for corrosion mapping shown in Figure Corrosion mapping results of the five lowest and highest remaining thicknesses’ are provided 3 with the corresponding ultrasonic scan. in Table 1. A difference 1 mm of material was recorded on remaining the samplethicknesses’ selected for are the corrosion Corrosion mappingofresults the fiveloss lowest and highest provided mapping between the maximum and minimum remaining thicknesses. A consistent decrease in the in Table 1. A difference of 1 mm material loss was recorded on the sample selected for the corrosion component thickness observed. mapping between thewas maximum and minimum remaining thicknesses. A consistent decrease in the The purpose behind measuring component thickness was observed. material loss due to corrosion in five vehicles was to obtain a benchmark. Results showed considerable due to corrosion in all samples The purpose behind measuring materialmaterial loss dueloss to corrosion in five vehicles was to collected obtain a from the vehicles. The benchmark of material the remaining help drawcollected an empirical benchmark. Results showed considerable loss duethicknesses to corrosionwill in all samples from the vehicles. The benchmark of the remaining thicknesses will help draw an empirical model to predict the life expectancy programme for the vehicles inside the shelters under specific environmental conditions. 16453 3 Sustainability 2015, 7, 16451–16464 model to predict the life expectancy programme for the vehicles inside the shelters under specific environmental conditions. Sustainability 2015, 7, page–page Sustainability 2015, 7, page–page Figure 3. BTR-60 (a) sample’s image and (b) ultrasonic scan. Figure 3. BTR-60 (a) sample’s image and (b) ultrasonic scan. 3. BTR-60 (a)scan sample’s and (b) ultrasonic Table 1.Figure BT R-60 samples’ resultsimage for 5 highest and lowestscan. thicknesses. Difference = 1.50 mm mm Difference = 1.50 Table 1. BT R-60 samples’ scan results for 5 highest and lowest thicknesses. Russian 60 and lowest thicknesses. Table 1. BT R-60 samples’ scan resultsBT—R for 5 highest Maximum Armour Thickness: 14 mm 60 5–7 mm MinimumRussian ArmourBT—R Thickness: Maximum Armour Thickness: 14 mm Sample’s Dimension Minimum Armour Thickness: 5–7 mm Length: 290 mm Width: 160 mm Sample’s Dimension S. No Remaining Thicknesses in mm No of Occurrences Length: 290 mm Width: 160 mm 1 5.00 16 S. No Remaining Thicknesses in mm No of Occurrences 2 5.10 46 1 5.00 16 3 5.20 123 2 5.10 46 4 5.30 322 3 5.20 123 5 5.40 420 4 5.30 322 6 6.10 17 5 5.40 420 7 6.20 5 6 6.10 17 8 6.30 3 7 6.20 5 9 6.40 4 8 6.30 3 10 6.50 3 9 6.40 4 10 6.50 3 4 4 16454 Sustainability 2015, 7, 16451–16464 2.2. The Environment Environment has a strong influence in the initiation and propagation of corrosion in metal structures; therefore study of the environments both inside and outside the shelters where the vehicles are stored has been conducted to relate corrosion activity within the context. It was observed that fluctuations in temperature and relative humidity inside the building are not viable for the structural health of the vehicles and presents a significant challenge for the vehicles’ protection against structural deterioration sustainably. 2.2.1. Environment inside the Shelter Inside the building, no measures are in place to control relative humidity during the year. However, temperature is kept between 18 ˝ C to 22 ˝ C during winter. It was observed that during the months from December–February, the relative humidity measured as high as 100%. Analysis of the environment inside the shelter has pinpointed endless cycles of surface wetting and drying due to temperature and relative humidity variations. The environmental variations in the shelter and atmospheric pollutants accumulated during operation plays a vital part in metal corrosion. Condensation happen on metal surface when temperature surpass 0 ˝ C, at relative humidity ě80%, this result in longer time of wetness (TOW) and ultimately cause atmospheric corrosion. In similar environmental conditions, a degree of corrosion is expected in the vehicles stationed inside the shelter [19–24]. 2.2.2. Environmental Analysis of Bovington Bovington is on the southwestern coast of England and is around seven miles from the English Channel. In Bovington, for 18 days of each month, considerable precipitation, fog, and rain are reported [25]. The relative humidity averages around 80% for most of the year, however in some months of the winter relative humidity reaches up to 100% [26]. The average high and low temperatures for the last 30 years (1981–2010) were 14.03 ˝ C and 8.11 ˝ C, respectively, the average temperature fluctuations observed during 1981–2010 were between 7 ˝ C to 22 ˝ C in summers and 2 ˝ C to 12 ˝ C in winters [25,27]. Vehicles stationed outside the shelters in open environment are enduring a wide variety of environmental conditions, such as soils, rain water, condensation, temperatures fluctuations and relative humidity deviations. All these dynamics create an atmosphere for vehicles’ corrosion. 2.3. Paint System Failures and Surface Contaminations The most common and effective methods of protection against corrosion is the application of paint system on metal surfaces. However, there are conditions under which the paint system starts to degrade, although failures in the paint system do not cause structural failures, they are, however, linked indirectly to the promotion of component failures through corrosion. When the paint system starts to fail, it allows the permeation of moisture to the substrate, which as a result causes corrosion, one of the major causes of structural degradation. Paint system failure was observed in many vehicles, as shown in Figures 4 and 5. 16455 Sustainability 2015, 7, 16451–16464 Sustainability 2015, 7, page–page Sustainability 2015, 7, page–page Figure 4. Challenger 1 failures in surface protection. Figure 4. Challenger 1 failures in surface protection. Figure 4. Challenger 1 failures in surface protection. Figure 5. Centurion-stridsvagon 104 paint system following a corrosion attack. Figure 5. Centurion-stridsvagon 104 paint system following a corrosion attack. Figure 5. Centurion-stridsvagon 104 paint system following a corrosion attack. It was identified that the phenomenon of corrosion was also influenced by the presence of It was identified and thatsub-surface the phenomenon corrosion also influenced presence of surface contaminants defects of such as slags,was sulphide inclusions by andthe corrosive pits. It was identified and thatsub-surface the phenomenon of corrosion was also influenced by the presence of surface contaminants defects such as slags, sulphide inclusions and corrosive pits. These factors alone and/or in combination were observed to be a serious issue. Sulphur, sodium, surfacefactors contaminants and sub-surface defects such as slags,tosulphide inclusions and corrosive pits. These alone and/or combination observed be a serious issue. Sulphur, calcium and chlorine wereinidentified on were the vehicles’ surfaces; these are classified as sodium, surface These factors alone and/or in combination were observed to be a serious issue. Sulphur, sodium, calcium and chlorine identifiedcorrosion, on the vehicles’ surfaces; these are classified as surface contaminants and resultwere in accelerated even at lower relative humidity [2]. calcium and chlorine were identified on the vehicles’ surfaces; these are classified as surface contaminants and result in accelerated corrosion, even at lower relative humidity [2]. contaminants and result in accelerated corrosion, even at lower relative humidity [2]. 2.4. Component Failures 2.4. Component Failures 2.4. Component Failures Component failure is not only the cause of vehicles’ malfunction but replacement is also a huge Component failure is not of only the causefailures of vehicles’ but Tiger replacement is also a huge financial burden. failure Brief results component frommalfunction King Tiger and 1 are presented Component is not only the cause of vehicles’ malfunction but replacement is also a here; huge financial burden. Brief results of component failures from King Tiger and Tiger 1 are presented here; inadequate component replacement was also identified in this research [1]. financial burden. Brief results of component failures from King Tiger and Tiger 1 are presented here; inadequate component replacement was also identified in this research [1]. inadequate component replacement was also identified in this research [1]. 2.4.1. King Tiger 2.4.1. 2.4.1. King King Tiger Tiger Sd Kfz 182 Panzerkampfwagen VI Ausf B was the official German name for King Tiger and is Sd Panzerkampfwagen VI BB was name King Tiger is also known as Tiger II. King Tiger was designed/Manufactured by Henschel & Son 1943– Sd Kfz Kfz 182 182 Panzerkampfwagen VI Ausf Ausf was the the official official German German name for for Kingduring Tiger and and is also known as Tiger II. King Tiger was designed/Manufactured by Henschel & Son during 1943– 1945 in NaziasGermany. Its first place action was Normandy in 1944. The King Tiger1943–1945 was one also known Tiger II. King Tiger wasofdesigned/Manufactured byJuly Henschel & Son during 1945 inmost Nazi Germany. Itsplace first place of action was the Normandy July The Tiger King Tiger was of powerful tanks to be during 2nd War;1944. together with was the Panther, it in the Nazi Germany. Its first ofdeployed action was Normandy inWorld Julyin1944. The King one ofone the of the most powerful tanks to be deployed during the 2nd World War; together with the Panther, it formed the lead of the German offensive in Ardennes [18,28]. formed leadBox of the offensive in Ardennes [18,28].after almost fifty years for corrosion Thethe Gear ofGerman the King Tiger was disassembled The GearasBox of the King 6. Tiger disassembled after almost years in formany corrosion investigation, shown in Figure The was gearbox showed various types offifty corrosion of its 16456 investigation, as shown in Figure 6. The gearbox showed various types of corrosion in many of its 6 6 Sustainability 2015, 7, 16451–16464 most powerful tanks to be deployed during the 2nd World War; together with the Panther, it formed the lead of the German offensive in Ardennes [18,28]. The Gear Box of the King Tiger was disassembled after almost fifty years for corrosion Sustainability 2015, 7, page–page investigation, as shown in Figure 6. The gearbox showed various types of corrosion in many of its components. Although King Tiger does notoperate operateanymore, anymore,itit is, is, however, however, structurally structurally components. Although the the King Tiger does not degrading due due to to corrosion. corrosion. degrading Sustainability 2015, 7, page–page components. Although the King Tiger does not operate anymore, it is, however, structurally degrading due to corrosion. Figure 6. Corrosion problem in King Tiger’s Gear Box Planet Gear. Figure 6. Corrosion problem in King Tiger’s Gear Box Planet Gear. 2.4.2. Tiger 1 Figure 6. Corrosion problem in King Tiger’s Gear Box Planet Gear. 2.4.2. Tiger 1 Tiger 1 was designed by Henschel & Son in Nazi Germany. Panzerkampfwagen Tiger Ausf. E Tiger 1 was1 designed by Henschel & Son in Nazi Germany. Panzerkampfwagen Tiger Ausf. E 2.4.2. Tiger was the official German designation and it is commonly known as Tiger 1. Tiger 1 participated in the was the official German designation and it is commonly known as Tiger 1. Tiger 1 participated in Tiger 1 was designed by Henschel Son Allied in NaziForces. Germany. Panzerkampfwagen Tiger Ausf. E 2nd World War against the former USSR&and This vehicle was captured in Tunisia. the 2nd World WarGerman against designation the formerand USSR and Allied known Forces.asThis vehicle was captured in Tunisia. was the official it is commonly Tiger 1. Tiger 1 participated in the Ostensibly, it is the last operating Tiger 1 in the World and is classified as a high value vehicle [18]. Ostensibly, it is War the last operating TigerUSSR 1 in and the World and is classified aswas a high value in vehicle [18]. 2nd Tiger World against thereplacement former Allied Forces. This vehicle captured The 1 original and engine pistons were evaluated for failures dueTunisia. to wear [1]. The Tiger 1itoriginal replacement pistons evaluated for failures due to[18]. wear [1]. Ostensibly, is the lastand operating Tiger 1 engine in the World andwere is classified as a high value vehicle It was identified that the original pistons, which were manufactured during 2nd World War, had It was identified the original pistons, engine whichpistons were were manufactured during 2nd The Tigerthat 1 original and replacement evaluated for failures dueWorld to wearWar, [1]. had enhanced wear resistant properties. The replacement pistons were used as a substitute in the Tiger 1 It waswear identified that the original pistons, which werepistons manufactured during World War, hadTiger enhanced resistant properties. The replacement were used as 2nd a substitute in the engine, whichwear failed catastrophically during normalpistons operation. This as failure couldinbetheattributed enhanced resistant properties. The replacement were used a substitute Tiger 1 to 1 engine, which failed catastrophically during normal operation. This failure could be attributed to inadequate composition. engine, material which failed catastrophically during normal operation. This failure could be attributed to inadequate material composition. Tiger 1 operates occasionally; inadequate material composition.when it is stationary, there is the possibility of corrosion build-up Tiger 1 operates occasionally; when it is stationary, there is the possibility of corrosion build-up in the engine, an example is shown 7. Corrosive-wear has a detrimental on the Tigersuch 1 operates occasionally; wheninitFigure is stationary, there is the possibility of corrosionimpact build-up in the engine, such an example is shown in Figure 7. Corrosive-wear has a detrimental impact on the in the engine, such an example is shown in Figure 7. Corrosive-wear has a detrimental impact on the engine performance in particular and on the Tiger 1 as a whole. engine performance in particular and whole. engine performance in particular andon onthe theTiger Tiger 11 as as aa whole. Figure 7. Tiger 1 corrosion build-up in the cylinder liner. Figure 7. 7. Tiger Tiger 11 corrosion corrosion build-up build-up in in the the cylinder cylinder liner. liner. Figure 3. Research Impact 3. Research Impact This research has led to the initiation and 16457 development of condition monitoring and protection framework of large vehicles against structural is the first evidence-based research This research has led to the initiation and deterioration. developmentThis of condition monitoring and protection that has been performed in this field and is directly linked to the identification of prevailing failure framework of large vehicles against structural deterioration. This is the first evidence-based research mechanisms, measurement and analysis of the failures, development of a new sheltered facility that has been performed in this field and is directly linked to the identification of prevailing failure Sustainability 2015, 7, 16451–16464 3. Research Impact This research has led to the initiation and development of condition monitoring and protection framework of large vehicles against structural deterioration. This is the first evidence-based research that has been performed Sustainability 2015, 7, page–page in this field and is directly linked to the identification of prevailing failure mechanisms, measurement and analysis of the failures, development of a new sheltered facility incorporating humidity temperature control, installationofofthe the environmental incorporating relativerelative humidity and and temperature control, installation Building upon the monitoring system and in-situ in-situ corrosion corrosion condition condition monitoring monitoring framework. framework. Building theoretical advances in the development of Condition Health Monitoring Programme CHM-PM and its success a wide range of complex failurefailure parameters has attracted increasing interests successininmodelling modelling a wide range of complex parameters has attracted increasing from defence, and gas, and aerospace industriesindustries [8–15]. [8–15]. interests from oil defence, oil automotive and gas, automotive and aerospace 3.1. Environmental Environmental Monitoring Monitoring and and Control Control 3.1. Relative humidity humidity and and temperature temperaturemonitoring monitoringsensors sensorsare arenow nowinstalled installed shelter at Relative in in thethe shelter at 10 10 locations, where the relative humidity and temperatures are constantly monitored. In addition locations, where the relative humidity and temperatures are constantly monitored. In addition to to this, based upon recommendations from research, a new conservation facility shown this, based upon thethe recommendations from thisthis research, a new conservation facility shown in in Figure 8 was recently built where temperature and relative humidity variations are kept Figure 8 was recently built where temperature and relative humidity variations are kept to to a a minimum. minimum. Keeping the the occurrences occurrences of of sharp sharp rises rises and and falls falls in in relative relative humidity humidity to to aa minimum, minimum, and and ideally ideally Keeping achieving an an optimum optimum level level (35%–45%), (35%–45%), is is an an important important factor factor with with respect respect to to keeping keeping the the vehicles vehicles achieving protected. This can be achieved through better ventilation, dehumidification and air conditioning. protected. This can be achieved through better ventilation, dehumidification and air conditioning. Optimum scale scale of of relative relative humidity humidity and and temperature temperature will will help help mitigate mitigate corrosion, corrosion, thus thus achieving achieving Optimum extended life for large vehicles and effectively retarding environmental assisted damage. extended life for large vehicles and effectively retarding environmental assisted damage. Figure 8. Collection of large that are now stored controlled environment in a new facility. Figure 8. Collection of vehicles large vehicles that are now within stored awithin a controlled environment in a new facility. 3.2. In-Situ Corrosion Condition Monitoring 3.2. In-Situ CorrosionofCondition Monitoring A framework in-situ condition corrosion monitoring based upon micro-linear polarisation resistors [29,30] shown in Figure 9 is developed and installed on the vehicles. This framework is able A framework of in-situ condition corrosion monitoring based upon micro-linear polarisation to detect materials degradation through corrosion in large vehicles in its early stages. This is one of resistors [29,30] shown in Figure 9 is developed and installed on the vehicles. This framework is able the novel systems to provide the opportunity to detect material degradation through corrosion in its to detect materials degradation through corrosion in large vehicles in its early stages. This is one of early stages cost effectively and non-intrusively. It can be defined as condition-based maintenance the novel systems to provide the opportunity to detect material degradation through corrosion in its (CBM), rather than scheduled-based maintenance (SBM), for corrosion mitigation before it becomes early stages cost effectively and non-intrusively. It can be defined as condition-based maintenance an unnecessary burden [31]. (CBM), rather than scheduled-based maintenance (SBM), for corrosion mitigation before it becomes In the initial stage, sensors are installed on two valentine vehicles. One of the valentines is an unnecessary burden [31]. permanently stationed inside the shelter, whereas the other operates sporadically. Data are collected regularly in order to monitor the structural degradation of these two vehicles in real time. The data acquired enables delivery of a critical evaluation of the structural health, which is useful in terms of predicting corrosion failures. This framework16458 provides an opportunity to protect the vehicles sustainably [32]. Sustainability 2015, 7, 16451–16464 In the initial stage, sensors are installed on two valentine vehicles. One of the valentines is permanently stationed inside the shelter, whereas the other operates sporadically. Data are collected regularly in order to monitor the structural degradation of these two vehicles in real time. The data acquired enables delivery of a critical evaluation of the structural health, which is useful in terms of predicting corrosion failures. This framework provides an opportunity to protect the vehicles Sustainability 7, page–page sustainably2015, [32]. Figure 9. 9. Three Three electrode electrode corrosion corrosion sensors. sensors. Figure 3.3. Empirical Empirical Modelling Modelling of of Paint Paint System System Failures 3.4. One of of the the main main reasons reasons for for paint paint system system failures failures in in large large military military vehicles vehicles is is edge edge delamination delamination One or the the gradual gradual removal of paint system from the metal surface in time. This This phenomenon phenomenon is is showed showed or in Figure 10a. Research Research was was conducted conducted to to develop develop aa holistic holistic model model [12] [12] for for paint paint system system failure failure in predictions because edge delamination as shown in Figure An 10b. advanced model to understand predictions becauseofof edge delamination as shown in 10b. Figure An advanced model to the cathodicthe delamination mechanism was developed. model contains system and blocks, inside understand cathodic delamination mechanism wasThe developed. The model contains system and the blocks therethe areblocks three interdependent processes; parallel Process of Cation Transport blocks, inside there are threeparallel interdependent processes; Process Modelling of Cation (Proc. CTM), Process(Proc. of Delaminated Coating Modelling [Proc. DCM] and Process Interfacial Transport Modelling CTM), Process of Delaminated Coating Modelling [Proc.ofDCM] and Propagation Modelling (Proc. IPM) as shown(Proc. in Figure Theseinprocesses represent (a) cation Process of Interfacial Propagation Modelling IPM) 10c. as shown Figure 10c. These processes formation (a) (b)cation reduction of oxygen and (c) mechanism of cation transportation. Every process in represent formation (b) reduction of oxygen and (c) mechanism of cation transportation. the model is aindiscrete algorithms with an ability ofwith inter-communication. This communication Every process the model is a discrete algorithms an ability of inter-communication. This is facilitated through duplexthrough channels transmitting r2, r3, signals r5 andr2, r6,r3,which represents communication is facilitated duplex channelssignals transmitting r5 and r6, whicha discrete delamination parameter. parameter. The interdependency of several parallel processes makes themakes study represents a discrete delamination The interdependency of several parallel processes andstudy understanding of quantitative agreement among delamination parameters easier. The obtained the and understanding of quantitative agreement among delamination parameters easier. The results are in close with the experimental data, its interpretation and numerical analyses obtained results areagreement in close agreement with the experimental data, its interpretation and numerical which have beenhave reported The proposed prediction prediction model willmodel be a useful analyses which been recently reported[12]. recently [12]. The delamination proposed delamination will resource forresource future research. be a useful for future research. Blistering is another reason why paint systems degrade in large vehicle that are in continuous operation in severe environmental conditions. An example of blistering in the paint system of a large vehicle is shown in Figure 11a. Research has been conducted to develop, model and predict initial paint system failure linked to blistering [8,9,14]. Both fracture mechanics classical theory approach and diffusion concepts have been incorporated through a generalised meso-mechanics modelling techniques to analyse blister initiation and propagation in two distinct stages. Diffusion concept have been deployed to represent the transport of corrosive species towards the interface of paint system and substrate, and facture mechanics concept to show blister growth in the form of circular crack propagation. A simple criterion is identified by using a developed interfacial toughness equation, which however does not include blister propagation on wider scale. The model has been validated using experimental methods showing a good qualitative agreement between the two. The previously mentioned blistering model was further modified in order to predict paint system failures due to unstable propagation of circular blisters in the form of worm-like patterns as a result of the development of compression and diffusion induced stress in harsh environments, as shown in Figure 12a. Paint system de-bonds from the substrate due to sufficiently large delamination, giving rise to blister, which consecutively induces the driving force on crack tip at interface. The crack tip 16459 Sustainability 2015, 7, 16451–16464 driving force decides the interface toughness, higher driving force account for low interface toughness and vice versa. The predictive model shown in Figure 12b presents non-axisymmetric perturbation of blister in to branching, which eventually results in worm-like pattern. The model was validated using detailed experimental study on a palladium-coated steel substrate, which allows the visualisation of delamination of paint system under the influence of both compression and diffusion of species. The investigation suggests that non-axisymmetric instabilities would develop at the crack tip during the propagation of blister, which eventually results in worm-like patterns, the patterns often observed in the delamination of thin paint systems. Sustainability 2015, 7, page–page Figure 10.10.(a)(a)Process (b) Schematic Schematicrepresentation representationofofpaint paintsystem system Figure Processofofactual actualpaint paint system system failure. failure. (b) failure.(c)(c)Representation Representation of delamination mechanism-modelling methodology. failure. ofcathodic cathodic delamination mechanism-modelling methodology. Blistering is another reason why paint systems degrade in large vehicle that are in continuous operation in severe environmental conditions. An example of blistering in the paint system of a large vehicle is shown in Figure 11a. Research has been conducted to develop, model and predict initial 16460 paint system failure linked to blistering [8,9,14]. Both fracture mechanics classical theory approach and diffusion concepts have been incorporated through a generalised meso-mechanics modelling techniques to analyse blister initiation and propagation in two distinct stages. Diffusion concept Sustainability 2015, 7, page–page equation, which however does not include blister propagation on wider scale. The model has been Sustainability 2015, 7, 16451–16464 validated using experimental methods showing a good qualitative agreement between the two. Figure 11. (a) Blisters on steel sample; and (b) modelling methodology for blistering. The previously mentioned blistering model was further modified in order to predict paint system failures due to unstable propagation of circular blisters in the form of worm-like patterns as a result of the development of compression and diffusion induced stress in harsh environments, as shown in Figure 12a. Paint system de-bonds from the substrate due to sufficiently large delamination, giving rise to blister, which consecutively induces the driving force on crack tip at interface. The crack tip driving force decides the interface toughness, higher driving force account for low interface toughness and vice versa. The predictive model shown in Figure 12b presents non-axisymmetric perturbation of blister in to branching, which eventually results in worm-like pattern. The model was validated using detailed experimental study on a palladium-coated steel substrate, which allows the visualisation of delamination of paint system under the influence of both compression and diffusion of species. The investigation suggests that non-axisymmetric instabilities Figure 11. (a) Blisters on steel sample; and (b) modelling methodology for blistering. Figure (a) crack Blisterstip on steel sample; (b) modelling for eventually blistering. results in would develop at11. the during the and propagation of methodology blister, which worm-like patterns, the patterns often observed in the of thininpaint systems. The previously mentioned blistering model wasdelamination further modified order to predict paint system failures due to unstable propagation of circular blisters in the form of worm-like patterns as a result of the development of compression and diffusion induced stress in harsh environments, as shown in Figure 12a. Paint system de-bonds from the substrate due to sufficiently large delamination, giving rise to blister, which consecutively induces the driving force on crack tip at interface. The crack tip driving force decides the interface toughness, higher driving force account for low interface toughness and vice versa. The predictive model shown in Figure 12b presents non-axisymmetric perturbation of blister in to branching, which eventually results in worm-like pattern. The model was validated using detailed experimental study on a palladium-coated steel substrate, which allows the visualisation of delamination of paint system under the influence of both compression and diffusion of species. The investigation suggests that non-axisymmetric instabilities would develop at the crack tip during the propagation of blister, which eventually results in worm-like patterns, the patterns often observed in the delamination of thin paint systems. Figure 12. 12. (a) Figure (a) Sample Sample showing showing the the propagation propagation of of blister blister in in to to worm worm like like pattern pattern under under increasing increasing resultant coupling stress (residual stress coupled with diffusion induced stress). Modelling resultant coupling stress (residual stress coupled with diffusion induced stress). (b) (b) Modelling methodology for for unstable unstable blister blister propagation. propagation. methodology 3.5. Public 3.4. Public Engagement Engagement Results fromthis this research aims to extend life of these high valuethrough vehicles through Results from research aims to extend the lifethe of these high value vehicles sustainable sustainable conservation methods. This that could thatpublic the general public and future generations conservation methods. This could mean themean general and future generations will be able to will be able to enjoy British and other engineering legacies for a longer time. enjoy British and other engineering legacies for a longer time. Public interaction includes a large YouTube following (over one million) about the Tiger Tank (2nd World War, German made, restored in Bovington) with concerns relating to durability and public 11 value of experiencing high value vehicles in operation. Tiger 1 is the last working example and demonstrated during displays at Bovington. Figure 12. (a) Sample showing the propagation of blister in to worm like pattern under increasing resultantResearch coupling (residual stress coupled with diffusion induced stress). (b) Modelling 3.5. Further andstress Grants methodology for unstable blister propagation. This project has attracted immense attention from academia and industry within the United Kingdom across Europe. The research also has been perceived by the general public as a high 3.5. Public and Engagement quality collaborative study, which has been focusing on the protection of high value vehicles with Resultscultural from and this historic researchbiographies aims to extend life and of these value vehicles through significant in Greatthe Britain acrosshigh the World. sustainable conservation methods. This could mean that the general public and future Large vehicles that are currently used by industries, defence and the public sector generations display the will be able to enjoy British and other engineering legacies for a longer time. same modes of failures over a specific time. Through an understanding of this research, there will be an opportunity to phase-out degradation problems that may not be predictable through conventional methods. 11 16461 Sustainability 2015, 7, 16451–16464 Findings from this research helped to secure further grants including £2,560,600 for new conservation facility at Bovington, £20,000 for research into flow assisted corrosion failures, £23,000 for in-situ corrosion condition monitoring and £24,000 for corrosion health monitoring using wireless sensor technologies. 4. Conclusions The outcomes from this research indicate wide ranging contributions in-terms of identifying failure mechanisms, finding solutions to the increasing problems in large vehicles, and implementing an optimised approach of protecting and sustaining large vehicles. Although the past working environment and operating duration of the vehicles is very complex to track, the damaged caused due to corrosion has been recorded. Figure 1 displays the magnitude of corrosion and the possible consequences if preventative measures are not taken. During this research, factors linked directly or indirectly to structural failures such as environment, component and paint-system failures were analysed. It was revealed that environments outside and inside shelters were not sustainable for the longevity of the vehicles. Variations in environmental parameters play a pivotal role in material degradation. Paint-system failures were found to be linked to structural damage and a major concern for vehicles’ durability. Vehicles are exposed to the outside environment from time to time, which may result in the accumulation of surface contaminants. In the likelihood of an inadequate paint-system, atmospheric corrosion could occur, even when vehicles are stationed inside the shelters. Close proximity of Bovington to the English Channel results in rain, wind, temperature, relative humidity variations and airborne salts contents. For vehicles parked outside the shelters, it is important that adequate paints system is in place on the surfaces for protection against such conditions. The development of the framework to monitor temperature and relative humidity in shelters as a result of this research provides an opportunity to keep the environmental variation to a minimum when needed. Through better environmental control systems and condition monitoring techniques, the durability and longevity of the large vehicles can be enhanced. The research helped to identify component failures attributed to corrosion, inadequate material composition and design. Data obtained as a result of in-situ corrosion condition monitoring technique are important in the context of monitoring structural reliability in real time. This is a condition-based approach rather than a scheduled-based approach. This framework also provides the opportunity to look into materials behaviour under certain environmental conditions. The proposed empirical model provides a foundation for continued research within paint-systems failures. Through a five-fold research pattern of identifying, measuring, analysing, monitoring and protecting large vehicles against structural failures, a framework of an optimised approach to protect and sustain large vehicles against structural failures is initiated. Apart from contributing to research community and museums, this research has shown its impact on various sections of society, like the automotive industry. This research provides a model to protect and sustain large historic vehicles as valuable assets for the current and future generations. Acknowledgments: NanoCorr, Energy & Modelling Research Group at Bournemouth University acknowledges in kind support provided by Advanced Technology Centre BAE systems UK, The Tank Museum at Bovington UK and Analatom USA. The authors also acknowledge financial support through match funding by the Defence Science and Technology Laboratory UK and Bournemouth University. Author Contributions: Adil Saeed started the initial research in large vehicles. In this article, Adil Saeed has contributed to research in the corrosion damage evaluation, component failures identification, paint-system failures and environmental analysis. Main H. Nazir is currently contributing to research in paint system failures and condition monitoring techniques. In this article, he has contributed towards research in the in-situ condition monitoring and the development of the empirical model for paint-system failures. Zulfiqar A Khan (Associate 16462 Sustainability 2015, 7, 16451–16464 Professor) has led the successful completion of a recent project in corrosion of large vehicles as lead supervisor. He is currently leading a substantive research portfolio in corrosion, which is funded by major industrial partners and international higher education institutions (HEIs). He has made key contributions to the ideas of scientific approach and development of methodologies in corrosion. Conflicts of Interest: The authors declare no conflict of interest. References 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Saeed, A.; Khan, A.Z.; Hadfield, M.; Davies, S. 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