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Lightweight Sol-Gel Coating to Mitigate Galvanic Corrosion

Picture for Lightweight Sol-Gel Coating to Mitigate Galvanic Corrosion
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Aircraft reliability and maintainability are critical to their availability and operation. One of the biggest threats to aircraft availability is corrosion of aircraft systems. The annual cost of corrosion for Air Force aviation and missiles is estimated to be $5.67B dollars, or 23.6% of total maintenance costs for this equipment, and 2.1 million non-available hours. It is estimated that for defense acquisition programs 60 – 80% of the total life cycle cost is associated with the operation and support (O&S) phase.

Product Number: 51323-18758-SG
Author: Adam Goff, Charles Sprinkle, Ben Pinkston, Fernando Farelas, Ariel Farelas
Publication Date: 2023
$0.00
$20.00
$20.00

Galvanic corrosion on aircraft around mechanical fasteners represents a significant portion of total platform maintenance costs and contributes towards reduced operational readiness. Historical approaches to controlling galvanic corrosion involve protecting the anode (e.g. usually the aluminum airframe), but minimal efforts have been made at limiting the galvanic contribution at the cathode. There is a need to improve the galvanic corrosion control tool set across these platforms, and technologies that aid in controlling the available cathodic current density are a new approach. Luna Labs is developing a sol-gel based coating to mitigate galvanic corrosion around fasteners and other dissimilar materials by providing excellent physical and electrical barrier protection to corrosive environments. This sol-gel coating results in a highly cross-linked inorganic/polymer hybrid film with excellent impact resistance, flexibility, and toughness. It is also inherently chrome-free and non-hazardous. The coating is designed for drop-in fastener application and easy integration with common aircraft components. Corrosion tests have indicated a reduction in observed galvanic corrosion by 2-3 times less compared to that of bare fasteners. This reduction in corrosion will directly translate to cost savings through decreased maintenance of aircraft components and improved operational readiness. A technology development status update will be provided.

Galvanic corrosion on aircraft around mechanical fasteners represents a significant portion of total platform maintenance costs and contributes towards reduced operational readiness. Historical approaches to controlling galvanic corrosion involve protecting the anode (e.g. usually the aluminum airframe), but minimal efforts have been made at limiting the galvanic contribution at the cathode. There is a need to improve the galvanic corrosion control tool set across these platforms, and technologies that aid in controlling the available cathodic current density are a new approach. Luna Labs is developing a sol-gel based coating to mitigate galvanic corrosion around fasteners and other dissimilar materials by providing excellent physical and electrical barrier protection to corrosive environments. This sol-gel coating results in a highly cross-linked inorganic/polymer hybrid film with excellent impact resistance, flexibility, and toughness. It is also inherently chrome-free and non-hazardous. The coating is designed for drop-in fastener application and easy integration with common aircraft components. Corrosion tests have indicated a reduction in observed galvanic corrosion by 2-3 times less compared to that of bare fasteners. This reduction in corrosion will directly translate to cost savings through decreased maintenance of aircraft components and improved operational readiness. A technology development status update will be provided.

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Laboratory experiments vs Field experience – Localized corrosion performance of lean duplex stainless steel UNS S32202 in municipal wastewater treatment plants

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Picture for 96063 GALVANIC CORROSION IN OIL AND GAS
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Product Number: 51300-96063-SG
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