Multi-Layer Thin-Film Coatings for Aluminum Alloy Components

F&S Inc. proposes to develop advanced electrostatically self-assembled, multi-layer mixed media thin-film coatings to improve the corrosion resistance of aluminum alloy components and other material systems. To produce such corrosion resistive coatings, we will fabricate high performance polymers and inorganic oxide particles using unique chemical processing techniques, and then form them into thick multi-layer thin-film coatings. F&S and their two subcontractors have demonstrated both of these methods through prior research programs. Judicious selection of inorganic oxide and noble metal particle species, precise control of particle size and orientation, and multi-layer formation allows graded tailoring of the surface hardness and corrosion resistance of the coated surface. The proposed self-assembly process allows the rapid multi-layer thick-film build-up to thousands of individual layers and micros of total thickness at room temperature and pressure, and totally avoids use of volatile organic compounds. During the Phase I program, F & S will design coating properties, select nanoparticles, self-assemble designed coatings, and evaluate properties with respect to design goals. Litton and Virginia Tech will assist with corrosion test article evaluation and analysis of production upscaling methods. Commercialization cost-sharing by F&S is pledged.