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

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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 
























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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 


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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 


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2 / 14/2011 











/ flTTTM 


Test Setup - ASTM B117 Salt Fog Test chamber 



2/14/2011 


www.alumiplate.com 


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ASTM B117 - Definition of Failure 



4032 hrs 3456 hrs 1344 hrs 


2/14/2011 


www.alumiplate.com 


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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 


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AhnnSJ^m 

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 



umir taj 

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 


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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 


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/ 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 


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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 



umir taj 

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 


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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 


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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 


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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 


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/ 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 


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