Multifunctional UV (MUV) Coatings and Ce-based...
Transcript of Multifunctional UV (MUV) Coatings and Ce-based...
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Surface Finishing Workshop Feb 08
Multifunctional UV (MUV) Coatings and Ce-based Materials
Matt O’Keefe and Bill FahrenholtzMissouri S&TRolla, MO
John DeAntoniBoeing-Phantom WorksSt. Louis, Mo
Ben CuratoloLight Curable CoatingsBerea, OH
SERDP Project WP-1519Bruce Sartwell, Chuck Pellerin, Donna Ballard
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Surface Finishing Workshop Feb 08
Develop a Two Layer, Chromate-Free, Zero TRI/VOC/HAPs Corrosion Coating System
for DoD Metallic Substrates
Metallic Substrate
Chromate Conversion CoatingStrontium Chromate Epoxy Primer
Polyurethane Top Coat
Metallic Substrate
Non-Chromate Conversion Coating
Multifunctional UV (MUV)-Curable Coating
Current 3 Layer, Cr(VI)Based Coating System
2 Layer, UV CurableCoating System WithNo Cr(VI) and No VOCs
Technical Objective
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Surface Finishing Workshop Feb 08
UV Curable Coatingsand Inhibitors
Non-Chromate Pretreatments
Multifunctional UV(MUV) Coating
Conversion Coating
Characterization,Test & Evaluation
Integrated Coating/FinishingSystem Ready for Demonstration
Technical Approach
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Surface Finishing Workshop Feb 08
Background
Cerium Pretreatment Deposition Process Development
Al Panels Cleaning Spray Process
Water RinsingPost-SealingCoated Panel
Process Is Environmentally Benign and Developed to Be Compatible with Current Military and OEM Operating Procedures
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Surface Finishing Workshop Feb 08
Background
Oligomers
Monomers
Additives
PIAdditives – include adhesion promoters, corrosion inhibitors, fillers, pigments, dispersing aids, stabilizers, rheological agents
Photoinitiator (PI) – absorbs UV radiation and generates species that initiate cross-linking polymerization
Oligomers -determine the physical properties of the coating
Monomers - influence viscosity, cure speed, and physical properties
Identify Oligomer, Monomer, Photoinitiator and Additive Chemistry of a Multifunctional UV (MUV) Curable System
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Surface Finishing Workshop Feb 08
Identification Of Oligomer, Monomer, Photoinitiator, and Additive Chemistry For UV Curable Self-Priming Topcoat System
• Evaluate state of the art chrome free corrosion inhibitor technology• Evaluate Series Of Aliphatic Acrylated Urethane Oligomers That
Demonstrate Good Flexibility And Good Weatherability Properties
• Design of Experiments To Optimize Gloss And Other Important Properties Through Controlled Reaction Rates Of Monomers
- Acrylate Groups And Other Reactive Functional Groups- Monofunctional And Multifunctional Materials
Background
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Surface Finishing Workshop Feb 08
Introduction
Surface Preparation of Al 2024-T3 and Al 7075-T6 forCerium-based Conversion Coatings (CeCC) Investigated
Multifunctional UV (MUV) Coatings Deposited onto CeCCand CrCC on Al 2024-T3. Two Inhibitors, A & B, Investigated.
- Non-UV Coatings Used as Controls
- Inhibitor B was Repeated for Extensive Testing
- Also Investigated Trivalent Chrome (TCP) and Bare Al 2024-T3
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Surface Finishing Workshop Feb 08
• SubstratesAl 2024-T3Al 7075-T6
• DesmuttingAcetone
• DegreasingAlkaline cleaning
• DeoxidationAcid or Alkalineetching
CeCC Surface PreparationCritical To Non-Chromate CCs
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Surface Finishing Workshop Feb 08
Alkaline Clean
CeCC Surface Preparation
Acid Activate
• Alkaline cleaning (5 wt.%, 55°C)Oxide thickness ~25 nmSurface rich in Mg and Al
• Acid activation (1 wt.% H2SO4, 50°C)Oxide thickness ~5 nmSurface rich in CuExposed IMCs??
Al 2024-T3
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Surface Finishing Workshop Feb 08
CeCC Spray Deposition
40 Sprays12 Sprays 25 Sprays6 Sprays 1 Spray
• Alkaline cleaning40 spray-drain cycles required; ~300 nm thick
• Acid activationOnly 1 spray-drain cycle required; ~200 nm thick
Alkaline Cleaning Acid Activation
Al 2024-T3
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Surface Finishing Workshop Feb 08
Alkaline Clean, 40 Spray-drain cycles Acid Activated, 1 Spray-Drain Cycle
50 µm 50 µm
CeCC Spray Deposition
Fails After 3 Days ASTM B117
Al 2024-T3
Passes 7 Days ASTM B117
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Surface Finishing Workshop Feb 08
MUV CoatingsIntegrated Coatings -3000 Hour Salt Spray Results Round 1, 2024-T3
Cr(VI)Control
No Cr(VI)Control
Inhibitor BOn CrCC
Inhibitor BOn CeCC
Inhibitor AOn CrCC
Inhibitor AOn CeCC
Best Performance with UV Cured Inhibitor B - Inhibitor B Performance Better Than All Others, Including Cr(VI)
Non-UV UV Cured
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Surface Finishing Workshop Feb 08
MUV Coatings
Initial 60o
glossFinal 60o
glossDelta E
Inhibitor B 2.7 1.9 3.1
Inhibitor A 7.1 1.9 7.5
Chrome Control
2.0 1.8 1.6
Chrome free control
1.9 1.7 1.6
1000 Hours Xe Arc Weathering
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Surface Finishing Workshop Feb 08
MUV Coatings
Formula Monomer Inhibitor Reverse Impact (in-lbs)
1 A B 8
2 A A 2
3 B B 14
4 B C 16
5 B A 2
Reverse Impact Flexibility Testing
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Surface Finishing Workshop Feb 08
MUV Coatings
Chrome Control
Chrome free Control
MUV on CrCC MUV on CeCC
MUV on TCP CC MUV on Bare 2024
ASTM B117 – 2000 HoursInhibitor B Round 2
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Surface Finishing Workshop Feb 08
MUV Coatings
MUV on CrCC MUV on CeCC
Chrome Control Chrome free Control
SO2 Spray After500 HoursInhibitor BRound 2
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Surface Finishing Workshop Feb 08
MUV Coatings
MUV on CrCC MUV on CeCC
Chrome Control Chrome free Control
Filiform After1000 HoursInhibitor BRound 2
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Surface Finishing Workshop Feb 08
Summary
Developing Two Layer, Non-Chromate Corrosion Coating System With UV Curable Self-Priming Topcoat
• Spray Deposited Cerium-Based Conversion Coatings
- Surface Preparation Critical
- Influences Deposition and Performance
• Multifunctional UV (MUV) Coatings Evaluated
- Capable of Passing ASTM B117 Salt Spray Testing
- Additional Formulation Work to Optimize Properties