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MIL-DTL-64159 vs. MIL-DTL-53039: A Direct Comparison

24 Jun MIL-DTL-64159 vs. MIL-DTL-53039: A Direct Comparison

Posted at 05:47h in MIL DTL 53039, MIL DTL 64159, Military by
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Meeting CARC‐level requirements is absolutely vital and central to our work at Royal Coatings. MIL-DTL-64159 defines a two-component, waterborne polyurethane topcoat with stringent chemical agent and abrasion resistance for ground vehicles, while MIL-DTL-53039 specifies a single-component, moisture-cure polyurethane finish designed for similar harsh environments.

Continue reading to see our direct comparison of these specifications, which will cover corrosion resistance, application methods, substrate pretreatment, and testing protocols. We will also note all the key differences in their chemistry, equipment needs, cure times, and compliance obligations.

MIL-DTL-64159 Overview

We use MIL-DTL-64159 to specify a two-component, waterborne, aliphatic polyurethane camouflage coating with chemical agent–resistant (CARC) properties. This finish is approved as a topcoat for military ground vehicles and equipment, offering excellent chemical and abrasion resistance.

MIL-DTL-64159B defines film properties, color requirements, application methods, and testing protocols for Type II coatings, which meet Federal Standard 595 color chips and must be qualified on the applicable Qualified Products List (QPL) at contract award ChemsolCVG Strategy.

MIL-DTL-53039 Overview

MIL-DTL-53039 governs single-component, moisture-cure, aliphatic polyurethane coatings with CARC properties. These coatings are used as finish coats on military equipment and vehicles.

Type IX (Moisture Cure) coatings under the 53039E revision require no external heat cure. Instead, they cure at ambient humidity after application. MIL-DTL-53039E specifies application viscosity, color matching to Federal Standard 595, and performance tests such as adhesion, abrasion resistance, and corrosive fume resistance Valence Surface TechnologiesChemsol.

Comparative Corrosion Resistance

Both MIL-DTL-64159 and MIL-DTL-53039 provide CARC-level chemical and corrosion resistance, but their chemistries differ:

  • MIL-DTL-64159 (Type II Waterborne Polyurethane): Exhibits high resistance to solvents, chemicals, and abrasion when properly cured. Its two-component system forms a tight film that minimizes the permeation of corrosive agents. Typical corrosion testing follows ASTM B117 salt spray and SAE J2334 cyclic corrosion methods.
  • MIL-DTL-53039 (Type IX Moisture Cure Polyurethane): Offers comparable chemical resistance, with performance validated via EPA Method 311 for hazardous air pollutant (HAP) emissions and ASTM D1654 for scribe corrosion testing. Its single-component moisture-cure formulation achieves similar barrier properties after the full cure but may require longer dry times.

Both specifications mandate QPL qualification and define corrosive fume resistance under MIL-DTL-53039E and MIL-DTL-64159B, ensuring that coating systems prevent corrosion from chemical agents across a range of substrates ChemsolChemsol.

Application Processes, Equipment Needs, and Turnaround Times

  • MIL-DTL-64159 Application:
    • Mixing: Components A and B are combined at a 2:1 volume ratio. After mixing Part B into Part A for 3 minutes, up to 0.5 parts deionized water may be added to achieve target viscosity for spray equipment.
    • Equipment: Requires a high‐pressure airless or air‐assist airless spray system capable of handling waterborne two-component materials. Pumps, hoses, and manifolds must be stainless steel or epoxy-lined to prevent contamination.
    • Drying/Cure: Tack-free in 30–60 minutes at 77 °F/50 % RH; full cure in 7 days. Oven curing is not required but can accelerate throughput in controlled environments.
    • Turnaround: The typical turnaround is 5–7 business days, depending on batch size, drying area availability, and environmental conditions Superior Coatings of AmericaIntrepid Coatings – Intrepid Coatings.
  • MIL-DTL-53039 Application:
    • Mixing: Single-component; requires mechanical agitation (e.g., 15 minutes on a shaker) before use to address thixotropic behavior.
    • Equipment: Standard air-spray or conventional high-volume, low-pressure (HVLP) systems may be used. Because it is moisture-cure, no heated curing oven is necessary—ambient humidity facilitates crosslinking.
    • Drying/Cure: Tack-free in 30–45 minutes at 70–75 °F/50 % RH; full cure in 48–72 hours.
    • Turnaround: Typically 3–5 business days for small batches, though humidity and temperature can extend cure times Intrepid Coatings – Intrepid CoatingsSuperior Coatings of America.

Substrate Compatibility, Pretreatment, and Adhesion Considerations

  • MIL-DTL-64159 Pretreatment:
    • Ferrous Metals: Remove mill scale, rust, and oils via abrasive blasting to SSPC SP 10 Near-White Metal Blast. Follow with three‐stage phosphate pretreatment (iron phosphate) per TT-C-490.
    • Non-Ferrous Metals: Clean per SSPC SP 1 solvent cleaning; apply conversion coatings (e.g., MIL-DTL-81706 for aluminum).
    • Primers: MIL-DTL-53022C epoxy primer (ferrous) or DOD-P-15328D/MIL-PRF-23377J epoxy primer (non‐ferrous) to ensure adhesion.
    • Adhesion Tests: 180° peel and crosshatch adhesion per ASTM D3359; specific testing protocols are defined in paragraph 4.5 of MIL-DTL-64159B.
  • MIL-DTL-53039 Pretreatment:
    • Universal Approach: Remove contaminants via solvent wipe (SSPC SP 1). For rusted or oxidized surfaces, abrasive blast to SSPC SP 6 or better.
    • Primers: MIL-PRF-23377J epoxy polyamide primer is recommended. Alkyd-based primers are not permitted under Type IX due to incompatibility.
    • Adhesion Tests: Crosshatch per ASTM D3359 and pull-off adhesion per ASTM D4541.
    • Proper pretreatment is essential for both specifications to achieve 10-year corrosion resistance. Poor surface preparation will compromise the CARC system and may lead to delamination under field conditions Intrepid Coatings – Intrepid CoatingsIntrepid Coatings – Intrepid Coatings.

Environmental, Health, and Safety Compliance

  • MIL-DTL-64159 (Waterborne):
    • VOC/HAP: Compliant with MIL-DTL-64159B limits for low volatile organic compounds (VOCs). Waterborne chemistry drastically reduces HAPs, simplifying compliance with EPA Method 311.
    • Worker Safety: Requires NIOSH‐approved respirators for isocyanate exposure during mixing; waterborne formulation poses less fire hazard. Ventilation must meet NFPA 33 guidelines for waterborne paints.
  • MIL-DTL-53039 (Moisture Cure):
    • VOC: Typical VOC content is 3.1 lbs/gal (370 g/L), meeting MIL-DTL-53039E VOC requirements. Users must follow EPA Method 311 to document HAP emissions.
    • HAPS: Low HAP content but still requires proper breathing protection to avoid exposure to isocyanate vapors during application.
    • Fire Safety: Although single-component and nonflammable inside the container, once sprayed, surfaces may be combustible; grounding and bonding are required.
    • Both specifications require environmental documentation for each lot, including MSDS/SDS submission per FED-STD-313, disposal of waste per local regulations, and recordkeeping for DoD audits CVG StrategyPaintDocs.

Cost Factors and Pricing Considerations for Small Manufacturers

  • Material Costs:
    • 64159: Two-component waterborne polyurethanes generally cost $25–$30 per square foot (including primer). Waterborne resins may be slightly less expensive than moisture-cure but require additional catalyst and water.
    • 53039: Single-component moisture-cure polyurethane ranges from $30–$35 per square foot (including primer), as it is formulated to strict CARC tolerances and must be QPL-listed.
  • Labor and Overhead:
    • 64159: Requires additional labor for precise mixing and handling of waterborne components. Waterborne systems often need controlled humidity booths, adding to overhead costs.
    • 53039: Simplified two-step application reduces lab mixing time, but longer ambient cure times can increase cycle time per part.
  • Equipment Investments:
    • 64159: High‐pressure plural component spray equipment and mixing pumps.
    • 53039: Standard air-spray equipment suffices; no plural component pumps.
  • Minimum Lot Sizes:
    • We can accommodate batch sizes as small as 5 parts for either spec, with upcharges for smaller runs due to setup and cleanup.
    • Our pricing structure offers small manufacturers tiered discounts based on square footage and batch frequency. We provide transparent quotes that delineate material, application, and testing costs, ensuring budget predictability for our subcontracted customers.

Finish Characteristics: Durability, Color Options, and Surface Appearance

  • MIL-DTL-64159 Finishes:
    • Durability: After the full cure, the finish resists solvents and abrasive wear. Meets 2,000 hours of salt spray and 1,000 abrasion cycles per MIL-DTL-64159B.
    • Color: Flat, lusterless finish in FED-STD-595 camouflage colors (e.g., 34031 Aircraft Green, 33446 Dark Tan). Topcoat gloss is defined as 5–10 GU at 60° per MIL-DTL-64159B.
    • Surface Appearance: Uniform matte texture (<5 gloss units). Slight texture may be visible due to waterborne resin properties.
  • MIL-DTL-53039 Finishes:
    • Durability: High film build with excellent flexibility; resists blistering, cracking, and chipping per ASTM D4060.
    • Color: Flat, satin-matte in FED-STD-595 colors. Panels typically exhibit <8 GU at 60° per MIL-DTL-53039E.
    • Surface Appearance: Smooth, homogeneous film with no pinholes or orange peel when applied at the recommended thickness (2–3 dry mils).
    • Both coatings are CARC-level finishes, providing infrared reflectance control and decontamination compatibility. Color matching to OEM camouflage patterns is validated via spectrophotometry per FED-STD-595/Color requirements ChemsolSuperior Coatings of America.

Quality Assurance, Testing Protocols, and Certification Requirements

  • QPL Qualification: Both 64159 and 53039 mandate that every coating lot be sourced from a QPL-listed manufacturer. We only utilize QPL-approved raw materials to ensure compliance.
  • Laboratory Testing:
    • Adhesion: Crosshatch (ASTM D3359) and pull-off adhesion (ASTM D4541) with a minimum 4B rating.
    • Corrosion: Salt spray (ASTM B117) 1,000 hours with <5 percent creep from scribe.
    • Chemical Agent Resistance: MIL-DTL-53039E and MIL-DTL-64159B require chemical agent immersion and decontamination testing using DMMP or CW surrogates.
    • Thickness & Dry Film Measurements: Use X-ray fluorescence (XRF) gauges to verify 1.5–3.0 mils (53039E) or 2.0–3.5 mils (64159B) dry film thickness.
  • Documentation: We maintain batch records, MSDS, application logs, environmental readings, and test reports for DoD audits. All records are retained for 10 years as specified in MIL-DTL-64159B, paragraph 6.4, and MIL-DTL-53039E, paragraph 5.3.

By adhering to these protocols, we guarantee that every part meets DoD performance criteria before you receive your shipment.

Royal Coatings’ Support Services

We support small manufacturers through every stage of the coating process:

  1. Specification Selection: We analyze part function, end‐use environment, and customer requirements to recommend either the MIL-DTL-64159 or MIL-DTL-53039 coating.
  2. Color Matching & Sampling: We provide in-house spectrophotometry to match FED-STD-595 chips or OEM proprietary camouflage patterns, issuing sample panels for customer approval.
  3. Pretreatment & Primer Application: Our three‐stage phosphate pretreatment and epoxy primer systems (MIL-DTL-53022C, MIL-PRF-23377J) ensure optimal adhesion. We handle both ferrous and non-ferrous substrates.
  4. Coating Application & Curing: Utilizing high‐volume booth capacity (20′ × 20′ for liquid and 30′ conveyorized booths for powder), we apply topcoats under controlled humidity and temperature, minimizing downtime.
  5. Quality Control & Final Inspection: We conduct in-house ASTM B117 salt spray, adhesion, and DFT testing. Each lot is certified to relevant QPL standards, with documentation provided.
  6. On-Time Delivery & Logistics: Offering pick-up and delivery trucks across the West Coast, we expedite turnaround for critical aerospace and defense components.

At Royal Coatings, we enable seamless compliance with both MIL-DTL-64159 and MIL-DTL-53039. By integrating our expertise in applying MIL-DTL-64159 and MIL-DTL-53039 coatings, we enable you to confidently deliver CARC-approved parts to end customers on schedule and within budget. Contact us today to get your quote!