Corrosion properties of water based and high solids Aerospace coating systems. IMFAIR 09 10th & 11th June 2009 Peter de Bruin Akzo Nobel Aerospace.

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Corrosion properties of water based and high solids Aerospace coating systems. IMFAIR 09 10th & 11th June 2009 Peter de Bruin Akzo Nobel Aerospace Coatings

Content Trends in Aerospace industry because of HSE legislation. Aerospace substrates, structural and exterior. Morphology and corrosion of Aluminium. Corrosion protection of Aluminium. Developments in Aerospace structural coating systems. Developments in OEM Aerospace Exterior coating systems. Comparison Water based versus high solids product. Aerospace corrosion test methods. Specifications / corrosion requirements. Corrosion results Airbus structural coating systems. Corrosion results Boeing exterior coating systems. Conclusions.

Trends in Aerospace industry because of HSE legislation. Changes in VOC legislation: Maximum allowed VOC per product (ready-to-spray). Primers: max. 350 g./l. Topcoats: max. 420 g./l. Limitation of Emission of organic solvents per location. Reduction / replacement of Cr 6+ compounds. Chromate free substrate (aluminium) pretreatment. Chromate free corrosion inhibitors in Aerospace primers.

Aerospace substrates, structural and exterior. Aluminium alloys used in Aircraft construction. Aluminum alloy Composition (%) 1100 (Clad layer) 2024 (T3) 7075 (T6) Al > 99 ~ 93 - 94.5 ~ 89.5 Cu 0.12 3 - 4.5 ~ 1.5 Mg ~ 2.5 Mn ~ 0.5 Zn ~ 5.5 Others ~ 1 Tensile strength (psi) 13,000 70,000 83,000 Yield strength (psi) 5,000 50,000 73,000 Elongation (%) 35 18 11

Aerospace substrates, structural and exterior. Other possible substrates, both in construction and for rivets / fasteners are: Titanium Lithium Aluminium alloys Stainless steel Composite

Morphology of aluminum 2024T3 The alloy is inhomogeneous. It contains grains. Coating Alloy 1100 Alloy 2024 T3 Grain boundaries are sensitive for corrosion!!

Morphology of aluminum 2024T3 The surface is inhomogeneous. It contains cathodic and anodic area’s Ca 300.000/ cm²; ~ 4.5% of surface area!

Filiform corrosion Thread like corrosion between substrate and coating about 15 µm in depth. Necessary conditions - Susceptible Al-Alloy. (lit.: % Cu> 0.15% large effect) Al-Mg alloys less sensitive. - Pretreatment. - Damaging of coating. - RH >60% RH. - Initiator; Cl-, SO42-. - Presence of O2. - Sufficiently high temperature.