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

Repairs of IVD aluminum coatings are generally not possible because the weak-plasma deposition process requires parts to be coated in a vacuum. Until recent development of the low-temperature Kinetic Metallization (KM) spray process the only metallic processes being evaluated for aluminum coatings on steel have been oxygen-free organic plating (AlumiplateT?), Al-Mn molten salt bath electroplating, and Ion Vapor Deposition (IVD) aluminum. Inovati developed a corrosion protective aluminum composite (AlTransT?) coating that is currently applied to carbon steel racks using the KM powder spray process. It is anticipated that the environmentally acceptable KM process can be used to economically repair IVD aluminum coatings on aircraft components using various nonhazardous powder feedstock materials including a composite blend of aluminum with a transition metal called AlTransT?. The object of the Phase I research is to develop one or more nonhazardous coating formulations using the low-temperature KM spraying process as a means of depositing an economical and high-quality corrosion-resistant metallic coating on high-strength steels. This environmentally compliant coating will be used as a replacement coating for cadmium brush plating currently used to repair IVD coatings on military aircraft.