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 aerospace components including landing gear, electrical connectors and aluminum structural components. The thermal spray process will be optimized to deposit high density, corrosion resistant aluminum alloys on high strength steel, aluminum and other targeted materials and configured for coating of complex geometry surfaces, including non line of sight (NLS) and other configurations that have traditionally complicated thermal spray processes. The proposed Phase I program will leverage previous work to develop a corrosion protective system for aluminum cladding replacement and focus on applying a similar system for protection of high strength steels and other component materials. A blend of computational and experimental optimization routes will be employed to maximize corrosion protection, as well as extend component surface geometrical capabilities and overall system robustness and portability. Additionally, an important aspect of the Phase I research will be to gain further understanding of the effects of various processing variables as well as the concept capabilities and limitations in order to design a scaled up device for a Phase II program.