An Ongoing Challenge for the Department of Defense
An inevitable enemy threatens fleet performance and longevity—corrosion. It costs the Department of Defense (DOD) over $20 billion in military assets annually. Amid federal budget reductions, identifying efficient and cost-effective maintenance solutions is imperative for the DOD . The agency is also pressured to adopt environmentally compliant cleaning solutions as a part of the executive order to increase the sustainability of federal supply chains, achieving net-zero emissions from federal procurement by 2050.
Yet, outdated abrasive blasting methods continue to dominate the defense industry despite safety risks and environmental hazards. Sandblasting exposes professionals to an increased risk of silicosis, and it alone produces over $1.75 million tons of hazardous waste each year. The setup and breakdown processes for sandblasting are lengthy, abrasives are required, as well as numerous pieces of safety equipment. Hazardous waste must be contained before it can run off into the ocean, and the risk of exposure to contaminated media by nearby personnel and equipment is high.
Lasers Cleaning Saves the Day
In laser cleaning, the energy of a focused laser beam is used to ablate – break molecular bonds and vaporize – unwanted material, be it contaminants or coatings on a surface. The technology can effectively remove corrosion, residue, paint, and other substances without damaging the underlying substrate. This process is non-contact, controlled, and precise, allowing for the selective removal of unwanted layers.
Laser technology reduces the use of chemicals and abrasive media in cleaning processes. Basic PPE for laser cleaning is required and includes laser-rated goggles, gloves, and – when vaporizing toxic particles – a respirator. As a non-contact method, laser cleaning induces no mechanical stress during processing and requires no physical force beyond handling the blaster. This eliminates repetitive use injuries that mechanical cleaning methods are associated with.
Fonon Technologies’ DefenseTech laser cleaning systems are designed for cleaning, finishing, roughening and surface preparation applications. The upgraded DefenseTech series now features a compact scan head for easier handling, and smart overheat protection for added safety. This upgraded product line includes ruggedized, transportable handheld laser systems for on-the-go use and Class I enclosed systems for stationary applications.
“In our demanding market, innovation is key,” said Bryan Lee, Vice President of Fonon Technologies. “Our next-generation DefenseTech systems are a testament to our commitment to providing rugged, state-of-the-art solutions to our government clientele. With these enhancements, we are poised to expand into new markets and attract a broader client base.”
Introducing the DefenseTech Expeditionary Corrosion Kit
We’ve developed the DefenseTech Expeditionary Corrosion Kit – DTECK – for expeditionary military missions, which provides our DefenseTech, TAA-compliant laser cleaning systems housed with an A/C-powered, mobile container. The DTECK includes:
- DefenseTech Portable Finishing Laser (DTMF-1020) – a high-precision, handheld laser tool for speedy polishing, meticulous cleaning, and top-layer coating removal needs. Explicitly designed for marine vessels and equipment maintenance, this dual axis, air-cooled pulse laser system offers a small form factor and mobility, making it ideal for immediate MRO tasks in the maritime industry.
- DefenseTech Blaster Cabinet (DTMF-4020) – a Class I enclosed laser system with no additional PPE required. It incorporates the exclusive power of a fiber laser with a handheld laser-blasting head inside an enclosed 30” x 26” work area. Designed for safety and precision, the DTMF-4020 enables the removal of contaminants and polishing of various surfaces without exposing the operator to laser radiation or fumes released during the procedure. This versatile pulsed fiber laser system is available with custom configurations to suit specific component processing within the defense sector.
The DTECK ensures rapid, safe, and effective surface maintenance in both field and depot-level environments as it comes equipped with:
- Workstation with Desk and Cabinets
- Power Outlets
- Cage for Integrated Storage
- Generator
- Fume Extractor
- Air Compressor
- Hooks, Straps, And Brackets
Laser Cleaning Benefits to the Department of Defense
Powered by a high-energy laser, the system removes contaminants much quicker than conventional cleaning techniques. Laser cleaning allows servicemen and women to complete the task in less time than traditional methods and quickly get out of that environment. When the repair is carried out in a small, enclosed space, a fume extraction system must be added to trap fumes and hazardous particles.
The versatility of laser cleaning offers the ability to remove a variety of other contaminants and coatings, not limited to paint, oil, soot, grease, and mold. A laser system can also be used for pre- and post-weld treatments when repairs are done onboard a naval ship.
By replacing traditional abrasive blasting with laser technology, the DOD can significantly reduce expenses in association with surface preparation and corrosion control. DefenseTech laser systems do not damage the underlying substrate, increasing equipment longevity and decreasing aircraft downtime. They enhance the safety of military personnel and ensure compliance with environmental, social and governance (ESG) regulations aligning with DOD’s sustainability goals.
Laser Cleaning Safety Advantages
Laser cleaning is an innovative method of industrial surface processing that minimizes the risk of silicosis, a major cause of concern with sandblasting. We provide laser cleaning systems classified as Class I or Class IV according to the safety standards set by FDA’s Center for Devices and Radiological Health (CDRH).
Our laser cleaning systems sport extra security features including a manual reset, a key-locked power switch, and a remote interlock connector, which serve to prevent accidental exposure to laser radiation. In enclosed Class I configurations, we equip our systems with a fume extractor, a vacuum table, and safe viewing for safe observation of the surface treatment procedure.
Frictionless Transition to Laser Cleaning Systems
Transitioning to laser-based corrosion removal may be a logistical challenge, since it will require procedural updates and training programs to be set in place. However, the systems balance automation and user-friendliness to ensure effective usage without extensive retraining. The U.S. Navy has already demonstrated confidence in our systems by placing a second order this year, proving their effectiveness and compatibility with existing defense operations. This precedent supports the feasibility of broader DOD adoption with minimal operational disruption.
Military personnel are also adamantly familiar with containers, considering they are widely used in the military for the efficient movement of supplies and mandatory equipment. Containers are often even transformed into lodging facilities making the DTECK, a viable solution to DOD maintenance needs and its specific program requirements. It can also be customized and is already built for the 463L pallet system used across all branches of the government.