Plasma Processing for Repair of Ion Vapor Deposited (IVD) Aluminum Coating

Ion vapor deposited (IVD) aluminum coatings on aircraft and navy ship board components inevitably get damaged and require repair. A nonhazardous repair to brush cadmium plating is required that meets performance requirements of the IVD aluminum. A unique plasma energy source process that does not require any solutions can apply adherent pure aluminum as well as aluminum base alloy repair coatings to damaged IVD aluminum without melting or adversely affecting the IVD aluminum coating. The process has been cursory demonstrated and can be automated such that highly skilled specialty trained operators are not required for field repair. The process will be further developed in Phase I along with composition optimization of the pure or alloy repair coating, coated specimens corrosion and other screen tested, and sample coated specimens provided to the navy. An automated design for coating repair will be produced in Phase I for construction and demonstration in Phase II.