Development and Characterization of a New Hybrid Polymer-Nanoparticle Composite Coating for Corrosion Protection in Aerospace Applications

Much effort has been expended to develop coatings to replace toxic chromates used as pretreatments or pigments in aircraft coatings. There have been many claims for chromate replacement in primer or pretreatment for aircraft, although few functioning systems meeting specifications are presently in use. Polymer nanocomposite coatings (PNCCs), which use nanoparticles as fillers in polymers, possess synergistic properties of nanoparticles and polymers. Because of this unique feature, PNCCs have potential to meet the demand in replacing chromate coatings. Properties of PNCCs are greatly determined by the degree of nanoparticle dispersion within the polymer, which is a key to improving mechanical and barrier properties in nanocomposite coatings over pure polymer coatings. In particular, PNCCs with extremely high concentrations of nanoparticle fillers are promising for corrosion protection in various applications. However, it is still challenging to prepare uniform PNCCs with high loadings of nanoparticles because a high loading of nanoparticles tends to aggregate in an uncured and viscous polymer matrix. This problem is especially exacerbated when mixing with non-spherical nanoparticle fillers, even after reducing the viscosity of polymer at an elevated temperature. This project will develop a new process for producing PNCCs with uniform distribution of nanoparticles at extremely high filler concentrations via polymer capillary infiltration into a dense packing of nanoparticles without any mechanical mixing. New coating techniques derived from PNCCs would be used to protect ground/launch systems and spacecraft from degradation in high saline environments. This project will address NASA's Space Technology Mission Directorate mission roadmap technical area 13.2.1 “Corrosion Prevention, Detection, and Mitigation” to develop new corrosion prevention technologies that provide environmentally friendly corrosion resistant/protective materials, coatings, and systems that last longer, require lower maintenance costs, and create less environmental contamination. This research strongly aligns with Alaska’s S&T Research Priority 7 “Land transport, shipping, aviation, aerospace, and telecommunications technology”. NASA personnel in the Kennedy Space Center Corrosion Technology Laboratory agreed to collaborate with us on this project. In this project, we have four objectives: (1) In Yr 1, develop a tested procedure to generate PNCCs with a polymer matrix filled with high loadings of TiO2 nanoellipsoids (>40 vol%) on an AA2024-T3 Al alloy with homogenous TiO2 nanoellipsoids dispersity; (2) In Yr 2, measure the corrosion properties (corrosion rate, voltage, and current) of PNCC-coated AA2024-T3 in a 3.5 to 7 wt% NaCl solution against two influencing factors: the degree of salinity and anisotropy of the TiO2 nanoellipsoids with various aspect ratios (1 to 4); (3) In Yrs 2 and 3, measure the susceptibility indices and model the failure mechanisms of stress corrosion cracking of PNCC-coated and uncoated AA2024-T3 under constant strains (up to 0.2% plastic strain) and slow strain rates (10-8 to 10-7 s-1) in a 3.5 to 7 wt% NaCl solution and in an inert environment against two influencing factors: the degree of salinity and anisotropy of TiO2 nanoellipsoids with various aspect ratios (1 to 4); and (4) Demonstrate research sustainability, collaboration with NASA personnel, and new corrosion protection coating technology development tailored to NASA’s missions. Successful outcomes of this project: (a) develop a benchmarked coating procedure for PNCCs with extremely high concentrations of nanoparticles, resulting in improved anti-corrosion performance suited for NASA's applications, (b) reduce the cost of maintenance, inspection, and corrosion damage, (c) establish and strengthen collaborative partnerships with NASA researchers, and (d) prepare and submit proposals for research sustainability beyond this project, based on the project outcomes.

This is a mature technology (TRL 7+) — the realistic path in is usually NASA's Technology Transfer Program: licensing an existing NASA patent, or a Space Act Agreement to use NASA facilities/expertise directly. NASA also runs a startup licensing program with no upfront fee for companies formed to commercialize a specific NASA technology.

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