N102-146 TITLE: Field powder coating application

TECHNOLOGY AREAS: Materials/Processes

ACQUISITION PROGRAM: Radar Restoration, OMN, PE s/b 0702228N

OBJECTIVE: Develop a Powder Coating material, process of application, and prototype applicator that can be used aboard ship for in place application to apertures and similar topside metal fixtures.

DESCRIPTION: Two critical areas for successful field powder coating are (1) environmentally robust application techniques and (2) field curing technology and coating formulation. While commercially available technology can deliver and deposit powder to a metal surface, the spray pattern and over spray are unsuitable and impossible to direct in any but a controlled environment. Innovative techniques are required to allow the operator to keep the powder close to the substrate without allowing the electrodes to get close enough to cause arcing to a grounded substrate. Field application studies involving resin, catalyst and additives to optimize performance, and Nanotechnology need to be conducted and coating formulas will need to be developed and evaluated for suitability with the application techniques which minimize or eliminate current controlled substrate preheating requirements. Field curing technology and coating formulation of superior corrosion performance coatings must be developed and evaluated for field application.

PHASE I: Analyze and research current powder formulation technology to develop a powder coating formula to optimize anti-corrosive performance in harsh, marine environments for maximum life-cycle extension of treated assets. Experiment with various powder formulations to determine effectiveness for use with Governmental field application. Via analysis determine application process, recommend appropriate materials, and design a prototype to accomplish application for ship board in place application of the selected powder coating (s).

PHASE II: Develop and validate a prototype powder coating, Field Application process, and Curing system for repair of small areas. Develop appropriate manufacturing technology for producing uniform consistent product as well as developing capability for manufacture of the application technology for Governmental and commercial use.

PHASE III: Transition the Phase II technology to Navy in-service radar systems through the Above Water Sensor radar restoration program.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: A (mobile) local Powder Coating application can be applied to any metal surface Government or Industry.

REFERENCES:
1. MIL-C-5541E - Chemical Conversion Coatings on Aluminum and Aluminum Alloys

2. MIL-A-8625 F - Anodic Coatings for Aluminum and Aluminum Alloys

3. MIL-C-24712A Coatings, Powder

KEYWORDS: Powder Coating; Application; Field Curing; Plasma; Flame Spray; Localized Cure

** TOPIC AUTHOR (TPOC) **

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