Environmentally-Compliant Kinetic Metallization Coating Materials for Corrosion and Wear Protection of Military Aircraft and Weapon Systems

Coating materials and coating methods used to protect U.S. military aircraft and weapon systems from corrosion and wear are in need of environmentally benign alternatives in order to keep up with dynamic regulations associated with environment, safety, and occupational health. Thus, the Air Force is supporting research to develop alternatives to the dangerous materials identified on the OSD Emerging Contaminants Watch List or Action List. Inovati was awarded a Phase I STTR project to investigate alternatives that could replace hard chrome , cadmium, and tungsten carbide cobalt coatings with environmentally benign materials to provide superior wear and corrosion resistant coatings. Of the structural metals only alloys of Al, Fe, and Ti are not on either the Watch or Action List. All three coating systems with additions of hard-phase constituents not on the OSD lists were studied and tested in Phase I. Down selection to a corrosion resistant iron-base metal-matrix-composite coating is proposed for Phase II optimization as a wear resistant replacement for hard chrome and tungsten carbide coatings. Inovati is teaming with Aerospace Corp. to perform materials test and evaluation of optimized coatings under a Phase II STTR subcontract.