Development of Cad Plating Replacement with Zinc Nickel on High Strength Steel Components

In 2010, ES3/USAF qualified LHE Zn-Ni electroplating process to replace cadmium plating on Landing Gear components. Hill AFB implemented an LHE Zn-Ni plating line in 2013 to replace all cadmium plated components with follow-on plans to terminate all cadmium plating. The F-16 has many components that are coated with cadmiuma known carcinogen. The F-16 Program office has identified the wing attachment bolt, which is made from H-11 steel and cadmium plated, as a high corrosion driver, with a stress corrosion cracking risk that is unacceptable. Additionally, the FAA issued an Advisory Circular to remove H-11 structural components with materials that are less susceptible to stress corrosion cracking. The F-16 wings attachment bolts function as the primary structural component for attaching the wings to the fuselage. During installation and service, the protective cadmium coating is commonly removed or worn away, making the bolts much more susceptible to corrosion damage. During this phase II SBIR, ES3 will redesign the attachment bolt and test the effectiveness of Zinc Nickel as a replacement for cadmium. Additionally, ES3 will evaluate other structural components and fasteners on the F-16 to identify other areas where zinc nickel can improve safety and reliability of the corrosion protective system.