Development of Spray Costing Methods and Materials to Replace Aluminum Cladding of Aging Aircraft for Corrosion Protection

摘要

The objective of this AF STTR Phase I work was to develop spray coating methods and new coating materials for corrosion protection of aging aircraft. The requirements are that the coatings should be easily depot applied and also the temperature of the skin should not exceed 150 deg C during the process. This is to preserve the original temper of the substrate. Plasma spray and cold spray coating methods were selected for this study. The process parameters of the coating methods were optimized to meet the above requirements. The explored coating materials consist of crystalline materials AA 1100 for 2024-T3 & Al-2 Wt % Zn alloy for 7075-T6 and aluminum based bulk metallic glass (BMG) precursor materials Al-5Fe-5Gd & Al-8Ni-5Y (atom %). Crystalline coating materials were cold sprayed onto substrate coupons at ASB Industries, Barberton, Ohio. Plasma spraying of crystalline and BMG materials was done at FlU, Miami, FL. The evaluations of the coated coupons include microstructural characterization, tensile tests and corrosion tests. The results are summarized below.