James Garrett, Luna Innovations, Inc.
Primer systems on aircraft protect the integrity of the underlying aluminum alloy through a combination of corrosion prevention and corrosion mitigation. The primers must maintain excellent adhesion with the substrate to prevent water exposure and subsequent corrosion cell formation. In the event that a corrosion cell is able to form, corrosion inhibitors act to reduce the corrosion rate. Common entry points that lead to corrosion occur around aircraft seams and fasteners due to an inability of the coating to withstand deformation under continual pressurization, wing flexing, or take off and landings. Current primer systems that provide adequate flexibility and corrosion control contain high levels of volatile organic components (VOC) and chromate containing inhibitors. However, continually tightening VOC and chromate restrictions are reducing the usage of currently available high flex primer systems. To address these issues, a highly flexible aircraft primer containing a novel coating resin system and chromate free corrosion inhibitors is under development to provide the necessary adhesion, corrosion inhibition, and compatibility with existing topcoats required by the Air Force. The effort is focused on creating a sprayable coating system through novel resin development, corrosion inhibitor selection, and coating formulation.