Wednesday, December 5, 2007 - 11:00 AM

On Demand Release of Environmentally Safe Non-chromium Corrosion Inhibitors

Scott Hayes, Crosslink; Patrick Kinlen, Crosslink Polymer Research

Many of the current primers used for the corrosion protection of aerospace aluminum alloys contain hexavalent chrome, a known carcinogen, as a corrosion inhibitor, but increased regulatory pressure from governmental agencies is driving the search for alternatives.  At this time, no commercially available alternative has succeeded in completely replacing hexavalent chromium in aerospace applications.   Crosslink’s preferred approach is to use “smart inhibitors” based on electroactive polymers which respond to a corrosion event by releasing a nontoxic corrosion inhibitor on demand.  Besides lower toxicity, this could have the added advantage of providing longer lasting corrosion protection than standard corrosion inhibitors which are constantly depleted by dissolution and diffusion whether or not they are required to prevent corrosion. 

Smart coatings protect metals from corrosion by providing a self-repairing system that detects and responds to electrochemical processes responsible for corrosion. When corrosion events are sensed, the coating releases corrosion inhibitors to shut down the corrosion process.  This presentation will describe smart coating system strategies employing polyaniline, an electroactive polymer (EAP), for the corrosion protection of high tensile strength aluminum alloys important to the aerospace industry. These coating systems capitalize on two unique properties that EAPs possess, i.e. their ability to (1) conduct electricity and (2) bind and expel molecules or ions in response to an electrochemical potential. Our approach is to incorporate molecules as EAP dopants which when released inhibit oxygen reduction reactions responsible for pitting corrosion. Proposed mechanisms, progress in selecting inhibitors, and ASTM B117 salt fog results will be presented.