Development of Cad Plating Replacement with Alkaline Zinc-Nickel Electroplating for Threaded Fasteners/Components

The DoD uses cadmium and chrome plating and removal processes on aircraft, engine, and landing gear components; however, these processes present significant health risks and cost. Cadmium, a carcinogen is targeted for removal from the workplace by the Environmental Protection Agency and is currently subject to regulation under the Clean Air Act, Clean Water Act and Resource Conservation and Recovery Act. Hexavalent chromium is also a carcinogen as defined by the Department of Labor 29 CFR 1910.1200. This STTP effort combines four SBIR technologies for the elimination of cadmium and hexavalent chromium into an integrated process for repair and overhaul of aircraft components: 1- Pulse Automated Water Strip System, STTP 2010-26, SBIR Topic AF071-317; 2- Amorphous Composite HVOF, STTP 2010-27, SBIR Topic AF071-322; 3- Novel Cooling and Temperature Monitoring System, STTP 2010-28, SBIR Topic AF071-121; and 4- Low Hydrogen Embrittling Alkaline Zinc-Nickel, STTP 2010-29, SBIR Topic AF081-101. ES3 will identify candidate components for evaluating the four integrated processes; conduct an engineering requirement review to identify any additional testing requirements and execute the selected tests, support USAF program offices through the Engineering Requirements Review and Configuration Control Board process to secure approval for dem/val testing and in-service field evaluations/Tech data.