DON26BZ05-NV075 TITLE: High Performance Electrolytic Coating Touch-Up Repairs for Aluminum
OUSW (R&E) CRITICAL TECHNOLOGY AREA(S): Contested Logistics Technologies (LOG)
COMPONENT TECHNOLOGY PRIORITY AREA(S): Sustainment
PROJECTED CMMC LEVEL REQUIREMENT: Level 2 (Self)
OBJECTIVE: Develop a simple, cost-effective, and portable touch-up applicator for performing electrolytic conversion coating repairs to provide a robust corrosion protective coating for aerospace aluminum components and structures.
DESCRIPTION: Corrosion protection for aerospace aluminum primarily relies on two inorganic coatings: chromate conversion coating and anodize coatings. Anodizing provides a superior barrier against corrosion, especially in harsh salt-water environments. In contrast, chromate conversion coatings (e.g., Alodine, Iridite) offer less protection but are significantly easier to apply, requiring a simple, non-electrolytic chemical application.
This difference in application creates a maintenance challenge. Anodizing is a complex process generally restricted to depot or Original Equipment Manufacturer (OEM) production facilities. Field repairs on anodized components, which can comprise up to 5% of the surface area under MIL-PRF-8625, often fall back on the use of easier-to-apply chromate conversion coatings. Touch-up pens, in particular, are widely used in aviation maintenance, from large depots to resource-constrained fleet environments. However, when used on an anodized part, these chromate repairs create a point of weakness that is more susceptible to corrosion.
A third alternative, electrolytic conversion coating, has been developed to bridge the performance gap between these two methods. Recent studies at NAVAIR demonstrate that applying a small electrical current (several hundred milliamps per square foot) during the conversion coating process significantly enhances corrosion resistance. Currently, the equipment required for this process restricts its use to depot factories where chemical processing shops are available. This creates a need for a field-deployable solution.
This topic seeks the development of a portable touch-up method for applying electrolytic conversion coatings. The solution is critical for filling a technology gap for a method to apply, repair, and touch-up aluminum coatings at the fleet level, improving corrosion capabilities across all levels of aircraft manufacturing, maintenance, and rework operations.
The ideal solution should meet the following criteria:
• The method must prevent chemical spills, environmental release, operator exposure, and contamination of the maintenance area.
• The process should be simple, cost-effective, easy to deploy to fleet maintenance sites, and require minimal operator training.
• The process should generate minimal hazardous waste, and the equipment should be simplified and miniaturized as much as is practical.
• The resulting coating must meet or exceed the corrosion performance requirements of MIL-DTL-81706.
• The application method must not damage the underlying aluminum through pitting, fatigue loss, or other undesirable effects.
• Primary aerospace aluminum alloys are 2000, 6000, and 7000 series aluminum alloys. However, the application method must perform equally well on all aluminum alloys.
• The process must not use hexavalent chromium.
PHASE I: Develop and demonstrate the feasibility of a portable, touch-up application method for electrolytic conversion coatings. The effort will include the following tasks:
1. Design a concept for a portable electrolytic conversion coating application method suitable for touch-up repairs.
2. Prove the viability of the application method, evaluating key parameters such as coating effectiveness, ease of use, and the ability to deposit coatings in tight spaces like fastener holes and other small interior diameters.
3. Conduct initial studies to assess the corrosion performance and paint adhesion of the applied coating.
4. Deliver a final report detailing the design and feasibility results, along with a comprehensive test and development plan for Phase II.
The Phase I effort will include prototype plans to be developed under Phase II.
PHASE II: Develop, optimize, and validate a prototype system for applying electrolytic conversion coatings, focusing on the following key activities:
1. Based on the successful Phase I concept, fabricate and deliver a functional prototype system to NAVAIR for evaluation.
2. Further assess and refine key system parameters, including portability, material compatibility, process costs, and operator ease-of-use. The application method will be optimized to ensure successful coating deposition on a variety of part geometries.
3. Evaluate the coating method to ensure it does not cause adverse effects to the substrate, such as inadvertent pitting, etching, corrosion, or loss of paint adhesion. Conduct testing as applicable to meet the requirements of MIL-DTL-81706 and/or MIL-PRF-8625.
4. Seek additional funding from various sources to support a fatigue testing initiative aimed at generating preliminary data on this touch-up method.
5. Provide a comprehensive final report that documents the prototype's design, system performance, and all material testing results. Include a detailed plan for Phase III.
PHASE III DUAL USE APPLICATIONS: Transition the validated prototype into a fully commercialized, field-ready product for widespread military and commercial use. This phase will focus on the following activities:
1. Operational Demonstration: Demonstrate the system's effectiveness in real-world, on-aircraft repair scenarios on aluminum substrates. Final validation will ensure the product is ergonomic, easy-to-use, and does not cause detrimental effects to the base material or expose operators to safety or hazardous material risks.
2. Transition the finalized prototype into a commercially viable product ready for widespread distribution. This includes finalizing all licensing and intellectual property (IP) agreements necessary for a successful commercial launch.
3. Establish National Stock Numbers (NSNs) for the system, its chemicals, and any required consumables. This will ensure the product can be easily procured and deployed by Department of War (DoW) maintenance activities worldwide.
This technology has direct applications in both military and commercial aviation maintenance. As the use of electrolytic conversion coatings in aircraft production grows, the demand for a portable repair method will increase substantially. Anodizing and chromate conversion coatings are standard for protecting aluminum on a wide variety of commercial platforms, including airliners, helicopters, corporate jets, and general aviation aircraft. Since touch-up repairs are a routine maintenance activity across all types of aircraft, this technology would represent a significant improvement over existing methods, offering a more durable and effective corrosion protection solution for the broader aviation industry.
REFERENCES:
KEYWORDS: Electrolytic conversion coating; ECC; Chromate conversion coating; Touch-up repair; Anodizing; Brush anodizing; Inorganic coating; Aluminum
TPOC 1 : Howard Whang
(619) 545-7693
howard.whang.civ@us.navy.milTPOC 2 : Calvin Chi
(619) 545-7695
calvin.d.chi.civ@us.navy.mil
** TOPIC NOTICE ** |
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