Application of thermal spray coatings to aerospace structures
Reusable launch vehicles located by the ocean are subject to harsh seacoast environments before launch and immersion after splashdown at sea and tow back to the refurbishment facility. The use of various thermal spray processes for depositing corrosion and erosion protective materials to the alloy substrates has potential for enhancing the corrosion/erosion resistance and useful life of those expensive large reusable aerospace structures. Thermal spray processes such as high velocity oxygen fuel (HVOF), plasma, arc spray and conventional oxygen fuel spray and the IVD process (pure aluminum only) have been used to coat test panels and scrap flight hardware with various applied materials. Pure aluminum, aluminum/aluminum oxide matrix (DURALCAN), and pure zinc have been applied over 2219-T87 aluminum alloy, 4340 steel alloy substrates. Salt spray testing has been conducted in accordance with ASTM B-117 as well as beach exposure tests at Kennedy Space Center, Florida. Adhesion tests have been performed for all materials applied to the various substrates as well as monitoring of substrate temperatures during the spray process. The pure aluminum, zinc, and aluminum/aluminum oxide matrix material afforded excellent corrosion protection in both beach exposure and salt spray environments. in conclusion, tests and actual applications have shown that the various thermal spray processes and coating materials have significant potential for enhancing corrosion/erosion resistance and extending the useful service life of expensive aerospace structures exposed to marine environments. The ability to effectively repair damaged IVD aluminum coated substrates using arc sprayed material adds flexibility to the maintenance process. Due to the excellent adhesion and corrosion protection of the substrate, tests are underway to determine if chromate conversion coating can be eliminated prior to primer/topcoat application.
- OSTI ID:
- 115538
- Report Number(s):
- CONF-9404233-; TRN: 95:002927-0118
- Resource Relation:
- Conference: 75. American Welding Society (AWS) annual meeting, Philadelphia, PA (United States), 10-15 Apr 1994; Other Information: PBD: 1994; Related Information: Is Part Of 75th Diamond anniversary American Welding Society annual meeting; PB: 273 p.
- Country of Publication:
- United States
- Language:
- English
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