Innovative Corrosion Protection via Kinetic Metallization

High strength, heat treatable, aluminum alloys are typically used in military aircraft, however such components require a corrosion protection coating. Such alloys include the 2xxx and 7xxx series alloys with typical protective coatings applied via anodizing, cladding, or priming. Inovati proposes to investigate the feasibility of using the Kinetic Metallization (KM) process to apply specific coating formulations for corrosion protection of high-strength aluminum aircraft structures and components. It is anticipated that the environmentally acceptable KM process will be a breakthrough innovation for economically coating aluminum aircraft components without degrading structural performance. Various nonhazardous powder feedstock materials including commercially pure aluminum and a composite blend of aluminum with a transition metal called Al-Trans® will be evaluated and ideal formulations identified. The object of the Phase I research is to develop one or more nonhazardous coating formulations using the low-temperature KM spraying process and to begin testing of these coatings for qualification in Phase II. It is anticipated that this environmentally compliant coating will be used as a replacement coating for cladding and anodizing currently used to protect components on military aircraft.