TECHNOLOGY AREAS: Air Platform, Materials/Processes

ACQUISITION PROGRAM: PMA-265, F/A-18 / EA-18G, Hornet, Super Hornet and Growler Program

RESTRICTION ON PERFORMANCE BY FOREIGN CITIZENS (i.e., those holding non-U.S. Passports): This topic is "ITAR Restricted." The information and materials provided pursuant to or resulting from this topic are restricted under the International Traffic in Arms Regulations (ITAR), 22 CFR Parts 120 - 130, which control the export of defense-related material and services, including the export of sensitive technical data. Foreign Citizens may perform work under an award resulting from this topic only if they hold the "Permanent Resident Card", or are designated as "Protected Individuals" as defined by 8 U.S.C. 1324b(a)(3). If a proposal for this topic contains participation by a foreign citizen who is not in one of the above two categories, the proposal will be rejected.

OBJECTIVE: Develop and demonstrate a robust, durable, affordable and environmentally friendly Carbon Nanotube Technology (CNT) anti-corrosion coating that significantly reduces or eliminates critical aircraft component corrosion damage that does not require frequent periodic maintenance throughout the component service life in order to sustain effective corrosion damage protection.

DESCRIPTION: Navy aircraft utilize both paint and coatings on exposed structural components. An undesirable, though not totally unexpected side effect associated with the use of the paint and coatings has been the discovery of significant corrosion damage in multiple Fleet aircraft inducted for both Integrated Maintenance Concept (IMC) and Age Exploration inspections. Accordingly, platform Total Ownership Cost (TOC) is being significantly increased due to the required disposition and repair of corrosion damage in Fleet aircraft. Non-accessible forged aluminum parts are currently one of the biggest degraders from corrosion which is the primary focus substrate of this effort, but not limited to this substrate or part. Currently these parts are typically finished with a MIL-PRF-23377 high solids epoxy primer sprayed to a 0.6-0.9 dry film thickness. The coating should have corrosion performance meeting or exceeding hexavalent chromium coatings that meet MIL-PRF-23377 and compatible in electromagnetic performance with present conductive coatings. Specifically focusing on the feasibility of applying this coating to components fabricated from 7050-T74511 forged aluminum shall be assessed to the performance found in present primer specifications such as MIL-PRF-23377 and MIL-PRF-85582.

The Navy needs coatings that are capable of performing the mission in the electromagnetic spectrum but yet mitigate corrosion. Application should be by conventional spray methods both aerosol cans or pressurized pots and have the ability of being brushed on and touched up if damaged. The coatings need to be low in volatile containing compounds (VOC�s) and hazardous air pollutants (HAP�s). The ideal coating would have over a year shelf life for logistical reasons and be single component for ease of use in the fleet.

PHASE I: Develop a CNT anti-corrosion coating and demonstrate the feasibility of using it as a coating for structural aircraft components fabricated from forged aluminum alloy.

PHASE II: Develop, demonstrate and validate the technology developed under Phase I. Evaluate the approach through the fabrication and testing of a sufficient quantity of material property test coupons. Demonstrate this process on a representative part to show corrosion resistance.

Note: The prospective contractor(s) must be U.S. Owned and Operated with no Foreign Influence as defined by DOD 5220.22-M, National Industrial Security Program Operating Manual, unless acceptable mitigating procedures can and have been be implemented and approved by the Defense Security Service (DSS). The selected contractor and/or subcontractor must be able to acquire and maintain a secret level facility and Personnel Security Clearances, in order to perform on advanced phases of this contract as set forth by DSS and NAVAIR in order to gain access to classified information pertaining to the national defense of the United States and its allies; this will be an inherent requirement. The selected company will be required to safeguard classified material IAW DoD 5220.22-M during the advance phases of this contract.

PHASE III: Transition the CNT anti-corrosion coating technology to appropriate platforms.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: Minimizing or eliminating airframe corrosion damage in military and/or civilian aerospace applications offers the potential for substantially reducing overall Life Cycle Support (LCS) costs via reduced periodic maintenance. This technology is in demand for commercial aviation, as well as for commercial steel and aluminum structures.

REFERENCES:
1. MIL-PRF-23377, Epoxy Primer, High Solids

2. MIL-PRF-85582, Epoxy Primer, Waterborne

KEYWORDS: aerospace primer; carbon nanotube (CNT); Anti Corrosion Coating; CNT Coating; hexavalent coatings; forged aluminum

** TOPIC AUTHOR (TPOC) **

DoD Notice:   Between November 10 and December 12, 2010, you may talk directly with the Topic Authors to ask technical questions about the topics. Their contact information is listed above. For reasons of competitive fairness, direct communication between proposers and topic authors is not allowed starting December 13, 2011, when DoD begins accepting proposals for this solicitation.

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