Advanced Metalworking Solutions for
Naval Systems that Go in Harm's Way

Implementation of Improved Crack Repair Process for MRAP Vehicles has Begun


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An improved process to repair cracks in the upper structure of MRAP Cougar CAT I/II will reduce the cost and schedule associated with the current method. (PM MRAP photo)

R2659 MRAP Improved Crack Repair


This Navy Metalworking Center (NMC) Rapid Response project identified improvements for repairing high hard steel (HHS) armor hull structures at DoD depots. Specifically, the project team identified potential root causes of in-service cracking in structures used for ballistic protection in the upper hull of the Mine-Resistant Ambush Protected (MRAP) Cougar Category I and II vehicles used by the U.S. Marine Corps (USMC). The team’s findings support the requirement for highly regulated inspection and repair operations as well as improved metal processing during the manufacturing of the HHS used for structural applications.


Process Improvement:

The project team conducted in-depth evaluations of the HHS material in use on the USMC MRAP family of vehicles and identified mid-thickness issues and concerns. The team determined that handling, processing, and repairing of the HHS structures needs to be tightly controlled to minimize the potential for post-repair cracking. Following the recommendations of this effort, the USMC MRAP program funded the development of a detailed repair technical manual to better define third through fifth echelon repair operations.

Implementation and Technology Transfer:

Partial implementation occurred through general improvements to weld-repair operations conducted at USMC depots. Full-scale implementation will follow the completion of a separately funded effort to develop a USMC repair technical manual specific to the MRAP Cougar family of vehicles (planned to be completed 3Q FY17).

Expected Benefits:

  • Improved crack inspection and repair processes
  • Reduced re-work costs associated with re-cracking
  • Improved reset schedule per hull
  • Support for additional high hard steel assets
  • Support for future procurement of new vehicles


  • PEO Land Systems
  • NMC
  • ONR Navy ManTech
For more information, contact:
Mr. Robert E. Akans
Senior Technical Director