Triboelectric Discharge Metallization--A Solid-State Coating and Spray Forming Technology

A low temperature, and ecologically sustainable method for consolidating aluminum powders with other metallic powders to form pseudo-alloy materials was discovered as a result of Phase I research on Solid-state Spray Forming (SSF) sponsored by theBallistic Missile Defense Organization. Commercial applications for this technology have been disclosed through independent research and market analysis. In particular, the aluminum industry is interested in surface modification techniques for aluminumalloys that do not contaminate or metallurgically alter the substrate during deposition. Triboelectric Discharge Metallization (TDM) is the coating analogue of SSF that permits surface modification of these substrates with unique material properties. TDMenables coating of aluminum alloys that was heretofore only marginally achievable with conventional thermal and plasma spray methods. The military currently requires surface modification and coatings of aluminum alloys for thermal and optical control,corrosion protection, wear resistance, and joining. The object of the Phase II research is to develop the TDM technology for military and industrial applications by reducing the technical risks so that Phase III commercialization is assured. Design,fabrication, and characterization of a TDM engineering prototype system during Phase II is expected to accomplish this objective.The chief benefit of the TDM technology is an improved and lower cost method of coating and spray forming materials with uniquematerial properties. The first commercial products are anticipated to be TDM systems implemented within the aluminum industry to enable coating of aluminum alloys for joining, corrosion protection, and wear resistance.