This paper discusses the results of a test and evaluation program implemented to identify a replacement for a high volatile organic compound (VOC), solvent-based coating system used on steel and aluminum general purpose (GP) bomb fins. Details of the test methodology and data are discussed An overview of the economic analysis and the steps taken to implement a turnkey powder coating system into the production line of the general purpose bomb fins is given. Emphasis is placed on lessons learned from the testing and evaluation of a variety of coating systems, including; thermal spray, water-borne, high solids and zinc-rich coatings. Important environmental considerations for choosing a coating system are reviewed, such as VOC limits, waste removal and special safety precautions. A comparison of the newly proposed coating system and the current system is presented. Actual cost figures from the manufacturing facility are incorporated into this discussion along with reports from the field. Finally, test results obtained from the study of a low-temperature cure TGIC polyester powder coating are presented.

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