Corrosion Resistant Non-Toxic Coatings for High-Strength Arresting Gear Tailhook Components

The principal aim of this program is to develop non-toxic corrosion resistant coatings to replace cadmium for tailhook applications on the Joint Strike Fighter (JSF). These coatings need to be dense, effective at preventing corrosion of the alloy, and able to be deposited onto non line-of-sight areas. Coating compositions will be aluminum based alloys which have previously been demonstrated on steel substrates using Directed Vapor Deposition (DVD). The aluminum based DVD deposited coatings have previously demonstrated corrosion resistance, are dense with no porosity, have a relatively low modulus to promote coating adhesion, and importantly can be deposited onto non line-of-sight areas. Coating compositions will be optimized to the current tailhook alloy. Corrosion testing will be performed in accordance with the “High-Strength Steel Joint Test Protocol.” Successful demonstration of the corrosion protection during the Phase I effort will lead to a Phase II effort that would include additional qualification testing as well as the coating of components utilizing DVTI’s production scale coater. A significant outcome of this study is the establishment of non-toxic corrosion resistant coatings and coating processes that provide the required corrosion resistance while reducing the usage and exposure to toxic materials.