Improved Anti-Corrosion Coatings for Undersea Cable Connectors

Texas Research Institute Austin (TRI/Austin) first developed non-conductive coatings (NCC) for marine connector applications in the mid 1990"s. These coatings are applied by a plasma spray process, and the patented technology has reduced the cost of ownership for the U.S. Navy by reducing down time of submarines for replacement of failed connectors from cathodic or corrosion related mechanisms. In spite of the outstanding performance of the original Bond-Coat system, the application is limited to flat or cylindrical surface geometries due to the need for uniform coating thickness. Numerous nonsymmetrical outboard connector types are currently used in Navy Submarines that cannot be coated using the current technology. TRI/Austin Inc. proposes the development of a second generation NCC for marine connectors that will permit application to complex surface geometries. The technology developed by this SBIR will be capable of coating, with uniform thickness, surfaces with 90 degree angles. The process will also enable coating of connector inside diameters. TRI/Austin will be teaming with a major underwater connector manufacturer to develop materials that can be processed using conventional application equipment and procedures.