The design, development, plant integration and operation of an automated wire arc spray system to implement metallizing technology for corrosion protection of U.S. Air Force general purpose bombs is described. The zinc/aluminum metallized coating sealed with waterborne acrylic latex direct to metal (DTM) replaces the original solvent-borne primer-topcoat system to yield an environmentally compliant lifetime corrosion protection coating that eliminates the current requirement for stripping and re-coating munitions every 5 years. Conservative 20 year life cycle analyses predict substantial cost savings for the Air Force as well as the achievement of environmental compliance at the Kadena AB Bomb Renovation Plant in Okinawa, Japan.

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