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Development of Self-Healing Coatings for Corrosion Protection of Repaired Aluminum Components Following Dimensional Restoration

Description:

OBJECTIVE: Develop/demo coatings for sustained protection of repaired corrosion damaged aluminum components from further surface & /or galvanic coupled corrosion damage [self-healing coatings (SHC)]. App at all maintenance, repair, & overhaul levels of repair. DESCRIPTION: Solutions are being developed to reliably identify apparent and hidden corrosion on aluminum surfaces and components, clean corroded areas without leaving undesirable residues, and restore lost substrate material. Many products have been developed in academia and industry. Current status quo materials usually only perform one topic activity such as remove corrosion or SHC system. This topic will combine all of these activities instead of having to develop each concept from the beginning. This topic addresses the need to identify, qualify, and certify post-repair corrosion-inhibiting SHCs with self-mending properties in order to inhibit further corrosion. The SHC product must meet MIL-PRF-85285 and/or MIL-PFR-32239 for performance and environmental issues. Product application shall follow the parameters identified in general series technical order 1-1-8. Product is desired to have lower volatile organic compound levels and hazardous waste components than the current Mil Spec requirements. These Mil Specs will identify the basis for research conditions, testing, and evaluation. Product is desired to perform on aircraft materials such as aerospace aluminum alloys, titanium, and composites. It is critical to involve Depot and Air Force customers to address potential issues, i.e., production modifications and realignment requirements. Coating materials and application methods for sustained self-mending of corrosion on war-fighting systems must be quick, transportable, field deployable, financially viable, and reliable. PHASE I: Research post-repair corrosion coating materials application methods and equipment to accomplish long-term resistance to corrosion and self-mending limited damage. Demonstrate feasibility of approach with coupon testing. Conduct Technology Working Group involving industry, academia, and government agencies to review findings/recommend technically feasible solutions. PHASE II: Perform further concept refinement and process optimization, assisted with subscale prototypes. Design algorithms and test protocols to qualify SHCs for components and subsystems of representative geometries. PHASE III: Fully develop, qualify, and certify self-healing anti-corrosion material, process, and equipment in DoD. Collaborate with depot structural and material engineers to apply technology for components. Coordinate with Commands to develop applications applicable for operating bases for multi-service use. REFERENCES: 1. White, S.R. and Braun, P.V.,"Self-Healing Polymer Coatings,"Advanced Materials, 21, pp. 645649, 2009. 2. Shchukin, D.G., Zheludkevich, M., Yasakau, K, et. al,"Layer-by-Layer Assembled Nanocontainers for Self-Healing Corrosion Protection,"Advanced Materials, Vol. 18, Issue 13, pp. 16721678, July 2006. 3."Self-Healing Nanotechnology Anticorrosion Coatings as Alternative to Toxic Chromium,"Nanowerk Spotlight, July 2008. 4. Hughes, A.E., Cole, I.S., Muster, T.H., and Varley, R.J.,"Designing Green, Self-healing Coatings for Metal Protection,"NPG Asia Materials, 2, pp. 143151, 2010; doi:10.1038/asiamat.2010.136. 5. Presuel-Moreno, F. Jakab, M.A., Tailleart, N., Goldman, M., and Scully, J.R.,"Corrosion-Resistant Metallic Coatings,"Materials Today, Vol. 11, Issue 10, pp. 1423, October 2008.
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