Metalphoto IUID Environmental Survivability Testing Report Synopsis

Background

Since its introduction in 2005, the U.S. Department of Defense’s Item Unique Identification (IUID) program has grown significantly. Millions of assets have been tagged and registered and several NATO allies have adopted the IUID barcode platform. 

IUID, as outlined by MIL-STD-130, does little to define the types of label materials to use in each military operating environment. MIL-STD-130 only references durability in as far as the label must be “as permanent as the normal life expectancy of the item and be capable of withstanding the environmental tests and cleaning procedures specified for the item to which it is affixed.”

Because label longevity is critical to IUID (the value of the program collapses when labels are illegible or detach), the Naval Surface Warfare Center (NSWC), Corona Division IUID Center conducted a study of commercially available label materials (the IUID Environmental Survivability Testing Report). 

The report offers an unbiased, government-sponsored comparison of label durability in order to help project managers identify the best label material for their operating environment(s). This paper outlines the results as they pertain to Metalphoto, the material that earned more high scores than any other evaluated.

Study Design

The Item Unique Identification (IUID) Environmental Survivability Testing Report was conducted in two phases: the first published in August 2011 and the second in September 2012. The second phase was implemented in order to incorporate several new tests and label materials. In particular, adhesion to CARC paint, elevated temperature adhesion, UV exposure, pressure washing and new chemical exposure tests were added in phase two. Across both phases, 73 label materials were evaluated in 8 simulated operating environments.

The 73 materials were submitted by 18 companies. Submissions can be grouped into the following categories: 

All submitted labels contained information about the material and a 2D data matrix barcode required for IUID. Labels were evaluated using a MicroScan UID DPM Compliance verifier to the AIM-DPM-1-2006 standard. Using the verifier (vs. human observation) has the advantages of being both objective (quantitative, measured by a machine) and the established military standard for an acceptable barcode mark under MIL-STD-130. 

The 10 Metalphoto labels submitted varied by adhesive (3M 9485, 3M 9469, M 9672 LE and CARC adhesive), laminate (none vs. SandShield) and marking method (pre-print vs. YAG laser marked). It is important to keep in mind when considering Metalphoto that it can be customized with adhesives specifically suited to the bonded surface/application or laminates that enhance its chemical or abrasion resistance. As a raw material (vs. a pre-adhesive applied system), Metalphoto can be configured into a variety of customized label systems to address a variety of surface energies and overall applications. 

Initial Verification

Prior to each test, all labels were verified. Verification was used as a baseline for subsequent testing. In terms of pre-test verification, Metalphoto labels rose to the top due to the high-resolution capability of the material. Because Metalphoto is a photographic substrate, it is ideal for high-detail, small labels on small surfaces such as guns, sights and communication equipment. Additionally, Metalphoto’s resolution allows for micro print and other anti-counterfeit measures to be incorporated into existing labels and nameplates. 

Findings

Chipping

Labels were subject to a 50 foot drop (about 40 mph) of gravel in ever increasing amounts from 500 ml up. Labels were verified after each round and failure was the volume of gravel to reduce the UEC to zero.

Most labels failed with 6,500 ml or less gravel. Plastic labels were most subject to failure. However, a handful of labels stood out. In particular, Metalphoto with SandShield dominated the phase two results, surviving after 14,092 ml of gravel  2,291 ml more than the next best material. 

Pressure Wash

Rigid substrates like Metalphoto and DuraBlack stood up extremely well to pressure washing – across both high surface energy (HSE) and low surface energy (LSE) surfaces. In fact, Metalphoto and DuraBlack rigid 0.020” labels with 3M 9485 adhesive scored better than any other material tested. According to the Report, “Rigid labels tended to perform better in pressure wash than flexible labels. Greater label thickness and label rigidity reduces the tendency of the label to start peeling.” 

Top performers were all Metalphoto or DuraBlack rigid labels.

Adhesion (Peel/Shear Tests)

All rigid 0.020” thick Metalphoto labels were tested with a shear test vs. the peel test conducted on the flexible plastic labels. As such performance can’t be compared because the test methods vary. That said Metalphoto labels exhibit 30-118 lbs./in of adhesion strength. According to the Report, “High shear strength correlated well with pressure wash results. Rigid labels tended to perform better in pressure wash than flexible labels. Greater label thickness and label rigidity reduces the tendency of the label to start peeling.” 

Weather Tests

Weather – the cycling of UV-radiation, high to low temperatures, humidity and rain – is a common cause of label failure. Phase two incorporated a 6 month (February – August) weather test in the southern California desert. Over that period, researchers calculated that the labels were exposed to 4367 MJ/m2 (mega joules per meter squared) of total solar radiation, equivalent 45 cycles of MIL-STD-810G Method 505.5 procedure II accelerated testing with a weatherometer. 

Although this six-month period wasn’t enough to differentiate label performance (all labels were verifiable at the end), degradation was seen in three label types: CO13 (Cable Marker Thermoplastic from CodeSource), AB12 (UV High Resist Polyester from A2B Tracking Solutions) and IK10 (TT462 Polyimide Permanent Acrylic from Identco). 

Chemical Exposure

In the second phase, labels were subject to a set of 13 chemicals intended to represent the likely substances labels will come into contact with (in phase one, Acetic Acid, Hydraulic Fluid and MIBK were tested). 

Metalphoto tested in the top 90% of all labels evaluated. When protected with the SandShield overcoat, Metalphoto holds up to bleach better than Metalphoto alone; despite the durability of Metalphoto’s aluminum oxide coating, Metalphoto is susceptible to bleach. It is recommended to limit Metalphoto tags’ exposure to bleach or employing SandShield, Teflon or other liquid shedding agents to minimize exposure. 

In some cases, failure was attributed to adhesive detachment. As a rigid material, Metalphoto can be attached mechanically with rivets.

Salt Fog Corrosion

Salt fog corrosion testing did not differentiate the materials. 

Taber Abrasion

Abrasion testing was conducted with two 1kg weights for up to 2,500 cycles. All Metalphoto labels scored in the top 1/7th of the labels tested with the fewest amount of error corrections required. Subsequent testing indicates Metalphoto to be extremely abrasion resistant withstanding up to 8,000 cycles on a Taber Abraser. 

Temperature

Although no significant differences between the labels were observed at the 160°F and -40°F temperatures tested. However, Metalphoto can withstand exposure to temperatures up to 1,000°F which is why the material is specified for labeling aluminum ingots and on-engine and aerospace tags. 

Conclusion

Although no significant differences between the labels were observed at the 160°F and -40°F temperatures tested. However, Metalphoto can withstand exposure to temperatures up to 1,000°F which is why the material is specified for labeling aluminum ingots and on-engine and aerospace tags. 

Metalphoto’s durability comes from its photographic image which is sealed inside of the anodized aluminum, providing resistance to corrosion, sunlight degradation, abrasion, extreme temperatures and chemical exposure. 

The purpose of the Navy’s tests are to identify materials that fit the needs of a variety of programs, applications and combat environments. Although there is no material that dominates every test, Metalphoto photosensitive anodized aluminum did emerge as the best option for more application environments than any other material. Because real-world usage conditions are often unknown when a label is specified and applied, it is important to pick a material that will be strong in many environments. As such, the recent Corona studies confirm that Metalphoto remains one of the most durable and versatile identification materials available. 

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