Demonstration and Validation of Brush LHE Alkaline Zn-Ni as a Brush Cadmium (Cd) Alternative

US Department of Defense (DOD) branches utilize aluminum and steel alloys for components throughout the different weapon systems. Traditionally brush cadmium (Cd) plating is used for local touch up after Cd plating operations and during repair and overhaul. Both the Cd plating process and the hex-chromate conversion coating typically used have proven to be toxic (unlike other processes such as chromium plating, where a hazardous process yields a non-hazardous coating). Consequently, ES3 successfully completed research via SBIR topics AF071-320 and AF081-101 for Cd replacement with LHE Alkaline Zinc-Nickel Electroplating with non-hex chromate conversion coating for high and low strength steel aircraft general and threaded components and fasteners; and on aluminum and steel electrical connectors under SBIR topic AF161-007. ES3 will leverage lessons learned during these previous efforts to develop, test and evaluate brush plating chemistries that can be utilized in lieu of existing brush Cd and Zn-Ni chemistries currently approved. In Phase I, ES3 investigated and successfully developed brush Cd plating chemistry alternatives, including hex-chrome free conversion coatings, and conducted the feasibility study and testing necessary to demonstrate USAF preliminary evaluation criteria for steel and aluminum applications that were previously Cd or Zn-Ni plated or IVD Al coated. In Phase