Advanced Aluminum and Magnesium Anti-Corrosion Coatings for Secondary Power Systems Parts

Aluminum and magnesium Secondary Power System parts are subjected to harsh environments which result in corrosion of the part leading to part condemnation. Incorporating advanced coating systems that are capable of withstanding exposure to harsh conditions as well as compatible with both newly manufactured parts and overhauled parts could lead to improved longevity of parts and mission readiness for the war fighter, resulting in a larger payback per Air Force investment. Current methods for protecting Secondary Power System parts involves anodizing the part then applying a chromic conversion coating which is time consuming, expensive, and toxic while providing minimal protection to the part due to low thermal tolerance. Sporian Microsystems has extensively researched and developed advanced materials for harsh environments with a particular focus on photopolymer and silane materials which exhibit excellent thermal, mechanical, and corrosion/oxidation properties. The long-term objective of this proposed work is to leverage prior development efforts to mature this technology to the protection of Secondary Power System parts exposed to extreme environments. The Phase I effort will focus on performing a conceptual study and a business case analysis of producing relevant anti-corrosion coatings for large scale use. These studies will include: custom materials development and coating