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This specification covers the requirements for ion vapor deposited (IVD) aluminum on steel, titanium, and aluminum alloys.

CLADDING of steel parts or assemblies with aluminum, through the use of a recently developed process which has been in commercial operation for two years, is described in this paper. Successful plant and field experience indicates that it can be applied at room and elevated temperatures in various types of atmospheres. This new process was originally designed to offer corrosion resistance caused by the collection of leaded fuel gas condensates in exhaust systems, and for other parts requiring high-temperature oxidation resistance up to 1600 F. However, it has since been used in a wide variety of applications.

Environmentally friendly powder coatings have been used widely for primer coating and clear coating, but there is no precedent for its use for base coating. ...Environmentally friendly powder coatings have been used widely for primer coating and clear coating, but there is no precedent for its use for base coating. This time, we optimized the condition of surface treatment of pigment and hardening behavior of constituent resin in the melting process and succeeded in developing a metallic powder coating for aluminum wheels that fulfills the appearance and the quality requirements of aluminum wheels. ...This time, we optimized the condition of surface treatment of pigment and hardening behavior of constituent resin in the melting process and succeeded in developing a metallic powder coating for aluminum wheels that fulfills the appearance and the quality requirements of aluminum wheels.

The design and process of some reflective surfaces are such that certain areas of the target do not receive sufficient aluminum coating thickness. Reduced coating thickness results in decreased optical efficiency, and has led to increased thermal demands on the thermoplastic substrate. ...This paper seeks to quantify how reflectivity and substrate temperature are dependent on the thickness of the PVD metal coating, and thermal simulation tools are used to predict lamp temperatures for varying coating thickness of the reflective surface.

Data are presented describing the effectiveness of metallic platings and an aluminum filled organic based coating on fasteners to render the titanium-aluminum electrochemical couple inoperative. The aluminum enriched organic coating known as Hi-Kote 1 is shown to be more effective in minimizing corrosive attack on aluminum airframe structure in both saline and acidic environments. ...The aluminum enriched organic coating known as Hi-Kote 1 is shown to be more effective in minimizing corrosive attack on aluminum airframe structure in both saline and acidic environments.

Selective (brush) hard coating is a practical way of applying hard, wear resistant, and corrosion resistant hard coatings on aluminum. ...Selective (brush) hard coating is a practical way of applying hard, wear resistant, and corrosion resistant hard coatings on aluminum. The coatings are comparable in quality to tank hard coats, and they meet most commercial and government specifications.

Currently there are three different types of bore solutions for small engines. 1) High silicon aluminum running with cast iron piston rings and a coated piston 2) Cast iron liner fitted to an aluminum block or cylinder 3) Nickel composite coating on an aluminum liner, cylinder, or block. A new method and apparatus has been developed to reduce the manufacturing tasks and costs of a bore solution. ...This new method involves turning a liner from aluminum and coating with nickel-silicon carbide. For the finish honing, an apparatus was developed that enables a liner to be honed for interference or clearance bonded fit into the block or the cylinder. ...The first part addresses the manufacturing and installation of liners and the second part gives engine designers some specifics of nickel ceramic composite electrolytic coatings.

This paper depicts icephobic coating performances of 274 different coatings, including 11 grease-type coatings, which were tested over the past 10 years in various research projects at the Anti-Icing Materials International Laboratory (AMIL). ...The first method, the ice Centrifuge Adhesion Test (CAT), measures the force required to separate the accreted ice from the coating (e.g. adhesive failure). The test involves simultaneously icing, under supercooled precipitation, the extremity of bare reference and freshly coated aluminum samples. ...Overall, the performance of tested coatings over the years remains similar with a wide range of ARF values, 0.5 to 1000, corresponding to stresses between 0.8 MPa and 0.0005 MPa, respectively.

It is free of all highly regulated heavy metals and carcinogens. The coating can be applied by either dip-spin, dip-drain or spray coating processes, resulting in a dry film thickness of 0.3-0.4 mils (7.5-10 microns) which is silver in color. ...This paper describes the work done to develop an environmentally friendly coating which provides corrosion protection to fasteners and stamped parts. It is a water based, neutral pH, VOC compliant coating that contains zinc and aluminum metal flakes in an inorganic binder system. ...It is a water based, neutral pH, VOC compliant coating that contains zinc and aluminum metal flakes in an inorganic binder system. It is free of all highly regulated heavy metals and carcinogens.

Hot-dip galvanneal sheet is produced throughout the world and several companies have developed specific testing methods to evaluate the adhesion properties of the coating to the steel sheet. There is no universal standards for individual companies to compare the quality of their coating to other commercial products. ...There is no universal standards for individual companies to compare the quality of their coating to other commercial products. This paper reports on a light absorption technique to assess the galvanneal coating powdering characteristics after bend testing. ...This paper reports on a light absorption technique to assess the galvanneal coating powdering characteristics after bend testing. Specimens are taped and subjected to a bend test, and then the tape is stripped, placed on a glass slide and evaluated in a spectrophotometer.

Our approach is to apply a DLC coating on the piston running against an aluminum-390 bore thus eliminating the iron liners in a standard piston/bore system. ...Experimental data, using a pin-on-disk tribometer under unlubricated test conditions, indicate that the performance of the DLC coating against aluminum 390 exhibits superior friction resistance compared to aluminum-390 against cast iron; the latter material couple representing the materials currently being used in production for the piston/bore application. ...Moreover, by thermally cycling the DLC coatings we show that improved friction and wear properties can he maintained to temperatures as high as 400°C.

This paper addresses the use of novel aluminum-filled inorganic coatings on plain carbon steel or stainless steel fasteners in order to eliminate galvanic corrosion in structural assemblies incorporating dissimilar metals. ...This paper addresses the use of novel aluminum-filled inorganic coatings on plain carbon steel or stainless steel fasteners in order to eliminate galvanic corrosion in structural assemblies incorporating dissimilar metals. These coatings are described and compared with zinc plated fasteners and other metals in a galvanic series. ...In environmental testing, stainless steel fasteners and carbon steel fasteners coated with zinc and aluminum-filled coatings, are coupled with aluminum, tin, copper, and 300 series stainless steel. The results of these tests indicate that this sacrificial aluminum/ceramic coating system limits corrosion of steel fasteners more effectively than zinc platings.

Evaporators for automotive air-conditioning systems are being coated externally to improve corrosion resistance, water drainage, and reduce potential odor concerns. The coating durability and efficiency in achieving its corrosion resistance depends on the coating uniformity and adhesion characteristics. ...The coating durability and efficiency in achieving its corrosion resistance depends on the coating uniformity and adhesion characteristics. Good coating adhesion on aluminum surface can be achieved after freeing the surface from the oxide and flux residues. ...Evaporators manufactured by the Controlled Atmosphere Brazing (CAB) process have flux residue remaining on the surface, the presence of which interferes with the coating process and also affects the performance of coated components. A methodology to quantify the effect of high Nocolok flux residue on heat exchanger coating uniformity has been presented.

Abstract This article presents a finite element (FE)-based model to simulate the temperature swing phenomenon of Silica-Reinforced Porous Anodized Aluminum (SiRPA) thermal barrier coatings (TBCs). A realistic three-dimensional (3D) SiRPA coating microstructure is constructed based on the morphology of an experimentally grown coating structure, and the known relationship of geometry and anodization parameters. ...Also transient thermal analysis is conducted to model the temperature swing effect of the coating by comparing the temperature fluctuation of SiRPA coating with conventional Yttria-Stabilized Zirconia (YSZ)-based TBCs. ...A realistic three-dimensional (3D) SiRPA coating microstructure is constructed based on the morphology of an experimentally grown coating structure, and the known relationship of geometry and anodization parameters. The coatings’ thermophysical properties are first computed using the FE model.

This paper presents, chemistry, test data and processing procedures on a non toxic and environmentally friendly chrome-free conversion coating alternative with the same level of adhesion and secondary corrosion resistance as that found in chrome containing conversion coating systems. ...This paper presents, chemistry, test data and processing procedures on a non toxic and environmentally friendly chrome-free conversion coating alternative with the same level of adhesion and secondary corrosion resistance as that found in chrome containing conversion coating systems. Test data from military and independent sources will be presented on secondary coating adhesion, electrical conductivity, filiform and neutral salt-spray corrosion resistance as compared to chromate based systems .on magnesium, aluminum and zinc and their respective alloys. ...Test data from military and independent sources will be presented on secondary coating adhesion, electrical conductivity, filiform and neutral salt-spray corrosion resistance as compared to chromate based systems .on magnesium, aluminum and zinc and their respective alloys.

Accelerated tests for determining disbondment resistance are described and the results from these tests for a wide range of coatings are presented. Coating systems that are acceptable for stainless steel and stainless steel clad aluminum are identified. ...The need to manufacture bright or colored trim with the same tools has led to the development of various coating systems to color stainless steel or bimetal trim. This paper describes the mechanisms of coatings disbondment that can occur on trim. ...This paper describes the mechanisms of coatings disbondment that can occur on trim. Accelerated tests for determining disbondment resistance are described and the results from these tests for a wide range of coatings are presented.

Plasma Electrolyte Oxidation (PEO) technique is a fast growing approach to resolve the weight load in automotive industry by creating a thin layer of a ceramic coating on lighter alloys such as aluminum for different parts like engine blocks. Of course in a hot and corrosive environment such as an engine, the main concern would be corrosion and wear effects on the engine. ...The goal of this research is to study the effect of different factors such as solution type, power input variations and coating thickness on wear resistance of aluminum Al 319.

The experimentally determined fatigue properties were compared to conventional estimates based on tensile properties which ignore coating effects. The results of this work suggest that ductile coatings may enhance fatigue resistance, while brittle coatings may reduce fatigue life. ...The influence of coatings on fatigue behavior has been examined for the following commercially produced sheet steels: uncoated titanium stabilized interstitial-free (IF); electrogalvanized titanium stabilized IF; hot-dip galvanized aluminum killed, drawing quality (AKDQ); and galvannealed AKDQ. ...A dependence of crack development was observed and correlated to the microstructure and properties of the different coatings. Furthermore, a functional design relationship for each material was determined through stress-life analysis.

A new chemical process of forming a non-corrosive flux for aluminum brazing has been investigated. The flux is built up onto an aluminum surface in a layer form, which consists of K2AlF5·H2O or K2AlF5-H2O/Zn codeposition. The K2AlF5-H2O layer formed through a chemical reaction between the aluminum metal and an aqueous treating solution gives a good adherency to the substrate and acts as the flux for brazing. The codeposition flux has an advantage of eliminating a pre-zincplating for sacrificial corrosion, since a Zn diffusion layer is formed on the aluminum surface at the brazing process.