Alternative Method of Surface Activation of High Strength Steels for Electroplating

During the overhaul process of aircraft and landing gear at Hill AFB, various high strength (HSS) aircraft components must have surface plated coatings periodically replaced. Some of those coatings include chromium (Cr), nickel (Ni), electro-less nickel (E-Ni), cadmium (Cd), low hydrogen embrittlement (LHE ZnNi) and phosphate. To achieve acceptable adhesion properties from the plated coatings, the HSS surface must be activated and all corrosion/contamination must be removed by blasting the components with 120-grit aluminum oxide. After which, some plating process require that 300M HSS components, which has a high silica content, have additional activation in an ammonium bifluoride H2SO4/NH4HF2 bath. The ammonium bifluoride bath chemistry is intermediate rout to hydrofluoric acid, which is a very hazardous chemical, poses high risk to personnel, and is corrosive to the eyes, skin, and mucous membranes. Additionally, grit blasting, if not done properly, can be abusive to HSS landing gear/aircraft components and contaminated grit can cause galvanic corrosion. Consequently, during this SBIR Phase I project, ES3 proposes to complete the research necessary to demonstrate feasibility of replacing the current surface activation process with a alternative surface activation technology that is be safer for plating personnel and less abusive to landing gear/aircraft components.