Innovative Material (and Application Method) for a Hydrophobic/Oleophobic Coating to an Aluminum-Bodied Heat Exchanger

US Navy V-22 Osprey assets are highly susceptible to debris buildup on critical aluminum bodied heat exchangers. Operating in harsh desert or marine environments is the primary causes of debris buildup. A self-cleaning coating technology developed specifically for V-22 heat exchanger units will enable the aircraft to function more efficiently, and extend its operational range. We have identified an emerging Plasma Electrolytic Oxidation aluminum conversion coating process that transforms the metal surface into its own ceramic form. The ceramic state of the aluminum surface is able to receive our novel super-hydrophobic self-cleaning surface coating. Our new duplex coating technology has been evaluated for 3xxx series aluminum heat exchangers, and found to completely eliminate debris build up in harsh environments. In addition, to the delight of our sponsors, our developments also provide greatly reduced costs versus toxic aluminum anodizing and conversion coating techniques. We will provide our patented, environmentally benign, self-cleaning binary coating technology system to address all DoD needs and those of the global community for safer, yet completely effective systems to maintain the surface of V-22 heat exchanger units.