Non-toxic process for depositing high density, corrosion-resistant aluminum alloys on complex geometry components

This SBIR Program is aimed at the development of a non-toxic alternative to cadmium electroplating for corrosion protection of a variety of high-strength steel aerospace components including landing gear and other structural components. The thermal spray process will be optimized to deposit high density, corrosion resistant aluminum and aluminum alloy coatings on high-strength steel and configured for coating of complex geometry component surfaces, including non line of sight (NLS) surfaces that are difficult to coat with conventional thermal spray processes. The proposed Phase II program will continue the progress made by the Phase I effort to develop a suitable corrosion protective system for high-strength steels and progress the technology toward coating a variety of DoD components. The program will include an experimental effort focused on qualifying coating performance with respect to mechanical and electrochemical properties, chemical compatibilities, and ultimately performance in accelerated corrosion tests.