Kinetic Metallization - A Repair Process for Ion Vapor Deposition (IVD) Aluminum

The Naval Air Warfare Center is currently seeking environmentally acceptable methods of spray depositing aluminum coatings for field repair of damage to corrosion protective coatings on aircraft components. Thermal spray processes cannot be used for applying aluminum coatings because of its high oxidation susceptibility in hot thermal spray plumes. Field repairs of ion vapor deposition (IVD) aluminum coatings are currently restricted to brush plating processes, which are environmentally hazardous. With the recent development of the low-temperature Kinetic Metallization (KM) spray process, it is now possible to economically deposit metallic aluminum powders directly onto high-strength steels. AlTrans™ coatings (aluminum composites) provide improved adhesion to steel relative to pure aluminum, while simultaneously protecting the steel through sacrificial anodic reaction. The Phase I research successfully demonstrated that various AlTrans™ composite-coating formulations applied to high-strength steels provide adequate corrosion protection. The Phase II project will focus on the qualification of optimum AlTrans™ composite coatings and the development of a turnkey portable KM system that can be used for making field repairs to IVD aluminum coatings. This environmentally compliant coating will be used as a replacement coating for brush plating currently used to repair IVD coatings on military aircraft.