Effective Corrosion Resistant Coating for Aluminum Secondary Power System Parts

Many of the assets in Secondary Power Systems (for example, large housings, auxiliary power units, aircraft mounted accessory drives, fuel control units, emergency power units, jet fuel starters, hydraulic starter motors, and central gearboxes) are very costly and complex. Corrosion is an important factor causing the condemnation and expensive repairs of Secondary Power System parts. Many of these parts are exposed to harsh environmental elements that may intensify the corrosion conditions. Currently used corrosion resistant coating for aluminum components is based on anodization and Alodine coating in accordance with MIL specs. However, this method is not always sufficient to protect the parts from corrosion during their lifecycle. Therefore, a new corrosion resistant coating is needed to provide the corrosion protection to aluminum components necessary to last for numerous overhaul cycles. Our proposed approach offers unique, fast, and effective non-chromate corrosion protection of Secondary Power System aluminum components where healing materials respond to environmental stimuli without external intervention. This contrasts with the conventional anticorrosion coatings which are just passive barriers that prevent the interaction of corrosive species with a metal. During Phase I we will demonstrate the feasibility of our approach, including performing tests showing the long-term resistance to corrosion.