What does it mean when a $9 billion stealth destroyer comes in port appearing as if it has been left outside in the rain? One of only three Zumwalt-class destroyers ever constructed, the USS Michael Monsoor recently arrived in Yokosuka, Japan, with its hull smeared with noticeable corrosion and discoloration sparking a social media ridicule and a more serious discussion about the ship’s engineering, maintenance, and purpose.
For navy designers and military officials, the spectacle is something more than a mere cosmetic blemish. The Zumwalt-class was designed to be the epitome of naval stealth and firepower, its faceted tumblehome hull and composite deckhouse intended to disperse radar waves and reduce detection. Yet, as one Japanese social media user quipped, “you’d need courage to go into battle with this,” while others questioned whether such visible decay might compromise the vessel’s radar-deflecting capabilities. Formally, the Navy maintains the corrosion is “cosmetic wear” normal for a vessel of this age and size, and “doesn’t affect performance.” But when it comes to stealth engineering, even small surface imperfections can change radar signature, casting a legitimate shadow over whether the ship’s low-observable profile has been maintained.
Marine corrosion science does not have mercy. Saltwater acts as a powerful electrolyte, accelerating the electrochemical reactions that degrade steel hulls. Based on NACE International, marine corrosion costs the world $50 to $80 billion per year. Shipbuilders depend on a multi-layered shield: advanced epoxy and polyurethane coatings, cathodic protection systems with sacrificial anodes, and careful design to prevent water-trapping crevices. Even so, regular maintenance is key. If the original coatings are applied badly or maintenance is neglected, even the most sophisticated hull will begin to deteriorate. As one source points out, repairing the coating while the vessel is offshore can cost up to 100 times the cost of the first coating. For a vessel that has to hold together structurally and remain stealthy, the risk is particularly high.
The Zumwalt-class’s problems are deeper than rust on the surface. Originally planned as a class of 32 next-generation destroyers, the program was scaled to three ships as expenses mushroomed and mission needs changed. The showpiece 155mm Advanced Gun System, designed to provide precision fire support for amphibious assaults, was made obsolete when the Navy terminated procurement of its specialized ammunition at one time, the Long Range Land Attack Projectile was estimated to cost as much as $915,000 per shot. Consequently, the main guns of the ships are effectively useless, and the Navy has shifted its focus to a new mission: integrating hypersonic missiles under the Conventional Prompt Strike (CPS) program.
This refit is an achievement of naval engineering in itself. At Ingalls Shipbuilding, forward gun mounts are being knocked out and replaced with four enormous missile tubes, each able to carry three CPS hypersonic missiles, for a total of twelve. The work entails stripping out the gun magazine and loading systems, stiffening the bow, and adding new decks and support structures to support the 87-inch missile tubes. The hypersonic missiles themselves are technology wonders, utilizing rocket boosters to propel a glide vehicle to velocities in excess of Mach 5. Following release, the glide vehicle weaves erratically through the atmosphere, rendering interception by enemy defenses highly unlikely. As the Congressional Budget Office observes, “hypersonic weapons present an ideal choice for penetrating through even the densest air and missile defenses to strike high-value and potentially time-sensitive targets.”
But the challenges are daunting. Hypersonic missiles produce enormous heat 3,000°F and need sophisticated materials and strong thermal shielding. Their fitting onto a naval platform necessitates new launchers, weapon control systems, and major shipboard power and cooling system modifications. The Zumwalt’s integrated power system, capable of generating 78 megawatts of electricity, provides a unique advantage, supporting both current and future directed energy weapons. But with only three ships in the class, each packed with bespoke hardware, the cost of sustainment and upgrades is high. As one program manager put it, we’ve extended the combat system aggravation period by two years to accomplish this installation.
All its woes aside, the Zumwalt-class is still a ship of unparalleled promise. Its wave-piercing design, low radar signature, and next-generation sensors are unmatched on a vessel of its class. The envisioned hypersonic upgrade might finally make good on the promise of a next-generation surface combatant that can threaten enemies deep within contested areas. According to the Navy’s director of strategic programs,“the missile has to be what we call in-air launched because it’s so large. It’s not like any other type of missile. You don’t light this thing off inside.”
Nevertheless, appearance counts. Amid growing naval rivalry, the sight of America’s priciest destroyer, streaked with rust and the scars of an aborted mission, reminds us that even the most high-tech engineering has to deal with the unforgiving forces of nature, budget, and changing strategy. The Navy’s expectation is that, once refurbished, the Zumwalt-class will not only look the part but finally play it.
