DTIC ADA599442: Temperature Effects on Corrosion of Cr6+, Cr3+, and Non-Cr6+ Conversion Coatings on AlumiPlate, and AlumiPlate Implementations

INCORPORATED

Temperature Effects on Corrosion of Cr 6+ , Cr 3+ ,
and Non-Cr 6+ Conversion Coatings on
AlumiPlate, and AlumiPlate Implementations

Kelly Donaldson, AlumiPlate
ASETSDefense, Feb 2011, New Orleans, LA

2/14/2011

www.alumiplate.com

1

Form Approved
OMB No. 0704-0188

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1. REPORT DATE

14 FEB 2011

2. REPORT TYPE

3. DATES COVERED

00-00-2011 to 00-00-2011

4. TITLE AND SUBTITLE

Temperature Effects on Corrosion of Cr6+, Cr3+, and Non-Cr6+
Conversion Coatings on AlumiPlate, and AlumiPlate Implementations

5a. CONTRACT NUMBER

5b. GRANT NUMBER

5c. PROGRAM ELEMENT NUMBER

6. AUTHOR(S)

5d. PROJECT NUMBER

5e. TASK NUMBER

5f. WORK UNIT NUMBER

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES)

AlumiPlate Incorporated,8960 Springbrook Dr Nw Ste 105 ,Coon

Rapids,MN,55433

8. PERFORMING ORGANIZATION

REPORT NUMBER

9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES)

10. SPONSOR/MONITOR’S ACRONYM(S)

11. SPONSOR/MONITOR’S REPORT
NUMBER(S)

12. DISTRIBUTION/AVAILABILITY STATEMENT

Approved for public release; distribution unlimited

13. SUPPLEMENTARY NOTES

ASETSDefense 2011: Sustainable Surface Engineering for Aerospace and Defense Workshop, February 7 -
10, 2011, New Orleans, LA. Sponsored by SERDP/ESTCP.

14. ABSTRACT

15. SUBJECT TERMS

16. SECURITY CLASSIFICATION OF:

17. LIMITATION OF
ABSTRACT

18. NUMBER
OF PAGES

19a. NAME OF
RESPONSIBLE PERSON

a. REPORT

unclassified

b. ABSTRACT

unclassified

c. THIS PAGE

unclassified

Same as
Report (SAR)

22

Standard Form 298 (Rev. 8-98)

Prescribed by ANSI Std Z39-18

Ahnnfihms^

INCORPORATED

AlumiPlate® Electrodeposited Aluminum

■ Minneapolis, MN, USA

■ Established 1995

Technology developed, tested, qualified & implemented

■ 100% RoHS / REACH Compliant

Electrodeposited Aluminum Corrosion Protection Coating

“Green” environmentally friendly replacement for toxic
cadmium (Cd) plating (point of app, fly away, mro)

Higher performance than present HAZMAT (Cd, Zn, Ni)
corrosion protection technologies and any alternatives

■ Well Established Specifications

MIL-DTL-83488 & Program / Application Specific

I BellHelicopter

BAESYSTEMS

2/14/2011

www.alumiplate.com

2

INCORPORATED

Temperature Effects on Corrosion of Cr 6+ . Cr 3+ . and

Non-Cr 6+ Conversion Coatings on AlumiPlate . and

AlumiPlate Implementations

■ Test Conditions

■ Aluminum electroplate per MIL-DTL-83488, Class 2
(0.0005”/12.5p min. thk.) on 4130 steel 3” x 6” coupons

■ Conversion coat with Cr 6+ ,Cr 3+ , non Cr 6+

■ Baseline = NO conv. coat,

■ 1 type — Cr 6+ (commercially available)

■ 3 types — Cr (commercially available)

■ 3 formulations - CFP non Cr® + -> (provided by NAVAIR under CRADA)

■ Temperature exposure: 30C, 250C, 350C

■ Corrosion test per ASTM B117

■ Protocol

■ 24 hour bake cycle for temperature exposure ,^^0

Results are averaged across multiple B117 test runs

www.alumiplate.com

3

2 / 14/2011

/ flTTTM

Test Setup - ASTM B117 Salt Fog Test chamber

2/14/2011

www.alumiplate.com

4

ASTM B117 - Definition of Failure

4032 hrs 3456 hrs 1344 hrs

2/14/2011

www.alumiplate.com

5

INCORPORATED

Baseline = No Conversion Coat

ASTM B117 Hours to Red Rust

3000
2500
2000
1500
1000
500
0

30 C 250 C 350 C

AlumiPlate
over 4130
Steel per MIL-
DTL-83488,
Class 2
(0.0005"/12.5
u min.)

2/14/2011

www.alumiplate.com

6

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INCORPORATED

Cr 6+ Conversion Coat
ASTM B117 Hours to Red Rust

6000
5000
4000
3000
2000
1000
0

30 C 250 C 350 C

5040

1

ZG88

876

AlumiPlate
over 4130
Steel per MIL-
DTL-83488,
Class 2
(0.0005"/12.5
u min.)

2/14/2011

www.alumiplate.com

7

M

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IN CORPORATED

Cr 3+ Conversion Coat
ASTM B117 Hours to Red Rust

4500

4000

3500

3000

2500

2000

1500

1000

500

0

3856

■1

2412

1124

AlumiPlate
over 4130
Steel per MIL-
DTL-83488,
Class 2
(0.0005"/12.5
u min.)

30 C

250 C

350 C

2/14/2011

www.alumiplate.com

8

Non-Cr 6+ Conversion Coat
ASTM B117 Hours to Red Rust

4248

504

30 C
250 C
350 C

CFP-2

CFP-6

CFP-21

2/14/2011

www.alumiplate.com

9

/ flTTTM

All Conversion Coats at 30 C
ASTM B117 Hours to Red Rust

AlumiPlate
over 4130
Steel per
MIL-DTL-
83488, Class
2 (0.0005" /
12.5 u min.)

2/14/2011

www.alumiplate.com

10

All Conversion Coats at 50 C
ASTM B117 Hours to Red Rust

AlumiPlate
over 4130
Steel per
MIL-DTL-
83488, Class
2 (0.0005" /
12.5 u min.)

❖

So

Jb

>

&

&

,o>

2 / 14/2011

www.alumiplate.com

11

M

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INCORPORATED

1200

1000

800

600

400

200

0

All Conversion Coats at 350 C - ASTM B117

Hours to Red Rust

~nz4r

636

❖

$

<v <6

• Y o'

f <?

AlumiPlate
over 4130
Steel per
MIL-DTL-
83488,
Class 2
(0.0005"/
12.5 u min.)

2/14/2011

www.alumiplate.com

12

INCORPORATED

6000

4000

All Conversion Coats at All 3 Temperatures
ASTM B117 Hours to Red Rust

Baseline Cr6+ Cr3+ CFP-2 CFP-6 CFP-21

2/14/2011

www.alumiplate.com

13

INCORPORATED

Conversion Coat & Temperature Performance

Summary

In general, across the conversion coatings tested,
corrosion performance decreases as temperature
increases (new non-Cr 6 * CFP generally better)

Cr 3+ & non-Cr 6+ CFP provide equivalent or better high
temperature corrosion protection compared to Cr 6+

The non-Cr 6+ CFP formulations show promising high
temp corrosion protection when compared to Cr 3+
(WIP)

2/14/2011

www.alumiplate.com

14

A.ilTSKte

Status Update - Recent AlumiPlate
Implementations on Present Programs

PROGRAM

PROGRAM

B-2 Spirit

F-16 Fighting Falcon

BHT 4 Series Model 429

F-18 Hornet

M119A Howitzer

F-22 Raptor

RQ-4 Global Hawk

C-5 Galaxy

CH53K Super Stallion

(Landing Gear)

F-35 Lightning II

Joint Strike Fighter

(Landing Gear, LEFAS, Elec. Conn.)

US Army Initiative

- High Purity Electrodeposited

Aluminum to Replace Cd on Fasteners & Electrical Connectors

2/14/2011 www.alumiplate.com 15

Ahnnfihms^

INCORPORATED

Recent Applications — CH53K — Landing Gear

SIKORSKY CK-53K OVERVIEW

Images of AlumiPlate
coated CH53K landing
gear not shown for ITAR
reasons. Please contact
AlumiPlate for details.

Size comparison

New I a it rolor
head-'b lades .

□ CH-53K

□ CH-JttE

Campsite main
rotor blades

tMsIomelrlo main
rolor bead ^

Hy-h-ywifrj controls

Glass

cockpit

New-built! airframe

350mm wider
cabin section

Refuelling probe AAQ-29 1 FUR

New drive system
Large composite sponsons

Ballisiic proteetlon FLIGHT

2/14/2011

www.alumiplate.com

16

INCORPORATED

F-35 LEFAS Environmental Qual Tests (in order): Rain (2hr), Icing
(168hr), Humidity (250hr), SO Salt Fog (336hr), & Sand & Dust (9hr)

TTTTTIn Pn,

INCORPORATED

Recent Applications — Elec Conn

AlumiPlate finish on selected F-35 JSF
electronic components (Honeywell tmc)

LMA PH010
MIL-DTL-83488

2/14/2011

www.alumiplate.com

18

INCORPORATED

Recent Applications — Elec Conn

ELECTRICAL CONNECTOR SPECIFICATIONS

Electrical Connector Specifications that include “ Class P ” for Pure
Dense Electrodeposited Aluminum as a Cadmium Alternative

MIL-DTL-24308G

MIL-DTL-38999

MIL-DTL-83723

MIL-DTL-32139A
MIL-DTL-28840
MIL-DTL-22992G
AS85049

MIL-DTL-83513G

MIL-DTL-26482

MIL-DTL-3607C

2/14/2011

www.alumiplate.com

19

/ flTTTM

Recent Applications — Fasteners

Zn Plate
with Cr 6+
+ CARC

Topcoat

< -

AlumiPlate
with Cr 3+
NO

Topcoat

200

2"

k, 150

o

E ioo

.2

50

0

Cd & A1 = Same

75% of Proof Load (11,802 Ibf)

Tension (Ibf)

□ Cadmium w/ 30 Weight Oil (K=.14)

□ Aluminum w/ Everlube 9002 (K=.16)

■ Cadmium - Dry (K=.24)

■ Aluminum w/ Magni B18 Silver (K=.30)

□ Aluminum w/ 30 Weight Oil (K=.33)

Grade 10.9
M12 x 50mm
All from same heat lot
30 samples each test condition
T n T & GM9540P & etc.

2 / 14/2011

www.alumiplate.com

INCORPORATED

Elcctrodeposited Aluminum

Performance Status

■ Proven performance vs. Cd Cr 6+

■ (CH 3 C0 2 K ground runway deicers )

■ High temperature performance with Cr 3+ & non-Cr 6+

■ Potential lower lifetime costs (lower corrosion costs)

■ ESOH Friendly (at point of application & coating on product)

■ Commercially available (trl 7 +, mrl 8)

Implementation Status

■ Slow but steady adoption program by program (part by part)

■ Supply chain availability a challenge but being
addressed thru DPA Title III Project Request working
with a S.E. Michigan metal finishing company partner

■ New large capacity plating line targeted for late 2012

2/14/2011

www.alumiplate.com

21

INCORPORATED

Temperature Effects on Corrosion of Cr 6+ , Cr 3+ ,
and Non-Cr 6+ Conversion Coatings on
AlumiPlate, and AlumiPlate Implementations

Kelly Donaldson, AlumiPlate
ASETSDefense, Feb 2011, New Orleans, LA

2/14/2011

www.alumiplate.com

22