Browse Topic: Coating processes

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AMS120425-1AMS120425-00000000000000000000001 (Current)12/4/2025
AMS120425-1
A-10 Aircraft Oxygen Equipment Committee
AIR120425-1AIR120425-1 (Current)12/4/2025
AIR120425-1
A-10 Aircraft Oxygen Equipment Committee
Verifying large alternate product code for an AIR document - AIR112425-1AIR1124250000000000000000/NEW1--1 (Current)11/24/2025
Verifying large alternate product code for an AIR document
A-10 Aircraft Oxygen Equipment Committee
Advancing Helicopter Repair: Gamma's Innovative Materials for the U.S. ArmyF-0081-2025-03475/20/2025
Maintaining the operational readiness of military helicopters demands repair solutions that are fast, reliable, and adaptable. This paper presents the integration of Gamma Alloys' advanced metal matrix composites (MMCs) into additive manufacturing (AM) techniques - specifically Cold Spray and Friction Stir Additive Manufacturing (FSAM) - as a transformative approach to helicopter repair and replace for the US Army.
Peabody, Micah, Harrigan, William
These Speedy Cold Spray Machines Can 3D Print Vehicle Parts in War ZonesTBMG-5212212/1/2024
Optimizing a Chemical Vapor Deposition Process for a High-Performance Tungsten MaterialTBMG-498091/1/2024
Investigation of Al2O3-Ni coated cast iron brake rotors under modified brake dynamometer test standards2022-01-03093/29/2022
Due to the reduced or less-frequent usages of the friction brakes and the lower brake rotor temperature on electrical vehicles (EV), corrosion would much likely occur on brake rotors. Using hard braking to clean the corroded rotor surfaces often leads to extra rotor surface wear. Improvement in corrosion and wear resistance is an important technological topic to brake rotors for EVs. Many original equipment manufacturers (OEM) and their suppliers are exploring surface treatments including laser cladding and thermal spray processes on cast iron rotors to combat the corrosion issues. However, mentioned surface coating processes increase the cost of brake rotors and there is a need to search for cost-effective coating processes. In this research, a new Al2O3-Ni composite coating was proposed for preparation of a commercial cast iron brake rotor using both plasma electrolytic aluminating (PEA) and electroless nickel plating (ENP) processes. The added nickel was to fit in the intrinsic
Cai, Ran, Sun, Jiayi, Zhang, Jingzeng, Tjong, Jimi, Foots, Sean, Lavelle, Mark, Nie, Xueyuan
Electrical insulation property of an alumina coating on a bearing steel SAE 521002022-01-08793/29/2022
In recent years, bearing electrical failures have been a significant concern in electric cars, restricting electric engine life. The most frequent material used to make bearings is 52100 alloy steel. This work aims to introduce a coating approach for preventing electrical erosion on 52100 alloy steel samples. This paper summarizes the causes of shaft voltage and bearing currents. Meanwhile, the paper discusses standard electrical bearing failure mechanisms, such as morphological damages and lubrication failures. Alumina coatings are suitable for insulating the 52100 alloy steel samples because alumina coatings provide excellent insulation, hardness, and corrosion resistance, among other characteristics. Based on the research, this article briefly discusses employing plasma electrolytic aluminating to coat 52100 alloy steel samples, an eco-friendly and high-efficiency coating process. Coating experiments were conducted over different coating periods to determine the most appropriate
Deng, Dewei, Nie, Xueyuan
Tungsten Carbide-Cobalt Chrome Powder Agglomerated and SinteredAMS7882D (Current)10/1/2021
This specification covers tungsten carbide-cobalt chrome in the form of powder.
AMS F Corrosion Heat Resistant Alloys Committee
Tungsten Carbide-Cobalt Chrome Powder Agglomerated and SinteredAMS7882D-TEST-REC (Historical)10/1/2021
This specification covers tungsten carbide-cobalt chrome in the form of powder.
AMS F Corrosion Heat Resistant Alloys Committee
Radiation Effects on Electronics in Aligned Carbon Nanotube Technology (RadCNT)21AERP02_072/1/2021
Characterizing the fundamental mechanisms and charge transport phenomena governing the interactions between ionizing and non-ionizing radiation with carbon-based (nanotube and graphene) field-effect transistors (FETs) devices and integrated circuits (ICs). Defense Threat Reduction Agency, Fort Belvoir, Virginia The main objective of the RadCNT program was the characterization of fundamental mechanisms and charge transport phenomena governing the interactions between ionizing and nonionizing radiation with carbon-based (nanotube and graphene) field-effect transistors (FETs) devices and integrated circuits (ICs). This effort was supported through the fabrication of aligned single-walled carbon nanotubes (SWCNT) FETs at the University of Southern California's (USC) Nanotechnology Research Laboratory and through a collaboration with the Naval Research Laboratories (NRL) for radiation testing and expertise in radiation effects characterization. The RadCNT program concentrated on
Radiation Effects on Electronics in Aligned Carbon Nanotube Technology (RadCNT)TBMG-385322/1/2021
The main objective of the RadCNT program was the characterization of fundamental mechanisms and charge transport phenomena governing the interactions between ionizing and non-ionizing radiation with carbon-based (nanotube and graphene) field-effect transistors (FETs) devices and integrated circuits (ICs). This effort was supported through the fabrication of aligned single-walled carbon nanotubes (SWCNT) FETs at the University of Southern California’s (USC) Nanotechnology Research Laboratory and through a collaboration with the Naval Research Laboratories (NRL) for radiation testing and expertise in radiation effects characterization.
Electrocoat Compatibilities of Automotive SealersJ1969_202101 (Current)1/7/2021
This SAE Recommended Practice sets forth a method for determining the compatibility of automotive sealers with cathodic electrocoat primer.
Materials, Processes and Parts Council
Material Advances for LED Quantum Dot EfficiencyTBMG-3801311/1/2020
Developing efficient and cost-effective ultraviolet light-emitting diodes (LEDs), especially in the deepultraviolet (UV-C) is a long-standing goal of the photonics community. UV-C LEDs are of particular interest and could replace gas discharge lamps, revolutionizing disinfection systems, provide water purification, and facilitate non-line-of-sight communication. In light of the on-going global pandemic due to COVID-19, implementation of a rapid surface disinfection method in which chemical cleaning is impractical or not as effective is of critical importance.
Diamond-Like Carbon Coatings for High-Wear Medical ApplicationsTBMG-3806311/1/2020
In the universe of wear resistant thin films, diamond-like carbon (DLC) coatings have emerged as the ideal solution for demanding physical applications, such as medical devices and instruments, where components are under high loads or subject to extreme friction, wear, and contact with other parts.
T55 Gas Turbine Engine Bleed Band Actuator Housing Re-DesignF-0076-2020-1628110/5/2020
The continual replacement of the bleed band actuator caused a supply shortage resulting in production work stoppage. A re-design effort restored the actuator housing through rework modification of a sleeve repair. The re-design substantion is presented along with the qualification test and manufacturing process. Significant value engineering savings and increased supply readiness resulted from the re-design effort for the U. S. Army. However, the re-designed sleeved actuator housing became costly and inefficient over time and subsequently stopped. The overhaul discrepancy is still present on the newer T55 gas turbine engine model. A review of new repair technology available identified another solution that does not generate hazardous industrial waste. That solution is cold spray technology. Cold spray solid state additive technology is evaluated for re-design of the housing as comparison to the existing sleeve re-design. Cost decrease and manufacturing efficiency increase are both a
Cass, Wesley
Protecting the New Generation of Sensors and Electronics: Smarter and Smaller Requires Advanced ProtectionTBMG-3786410/1/2020
From advanced manufacturing operations to intricate consumer wearable devices, electronics are the heartbeat of many industries today. To meet growing demands for more advanced features and overall smarter devices, sensors, circuit boards, flex circuits, and other electronic components must continue to expand rapidly in their capabilities even as their packaging and the systems they are part of continue to shrink in size.
Nanomaterial Gives Robots Chameleon SkinTBMG-376209/1/2020
Anew film made of gold nanoparticles changes color in response to any type of movement. Its qualities could allow robots to mimic chameleons and octopi — among other futuristic applications.
Transparent Graphene ElectrodesTBMG-374428/1/2020
A new method of making large sheets of high-quality, atomically thin graphene could lead to ultra-lightweight, flexible solar cells and to new classes of light-emitting devices and other thin-film electronics. The manufacturing process involves an intermediate “buffer” layer of material that allows the ultrathin graphene sheet, less than a nanometer (billionth of a meter) thick, to be easily lifted off from its substrate, allowing for rapid roll-to-roll manufacturing.
New Coating Process Lights Porous Electronics and SensorsTBMG-373648/1/2020
Researchers have shown how to coat glass and plastic with porous titanium dioxide. The fabrication process is straightforward, the materials are cheap, and the ceramic’s gas sensing performance is considerably improved compared with current devices.
New Plasma Process for Surface Treatment of ImplantsTBMG-371186/1/2020
The medical device industry has long sought surface modification solutions that will improve cell growth and proliferation on titanium, polyetheretherketone (PEEK), and polymer artificial implants. In some cases, plasma sprays are applied. However, within the industry there is concern that small particles of the coating could be released into the surrounding tissue. Radiofrequency (RF) plasma is another alternative, but the process generates quite a bit of heat — a distinct disadvantage when processing polymer implants.
Tungsten Carbide-Cobalt Powder Agglomerated and SinteredAMS7881B (Current)5/6/2020
This specification covers tungsten carbide-cobalt in the form of powder.
AMS F Corrosion Heat Resistant Alloys Committee
Tungsten Carbide-Cobalt Powder Agglomerated and SinteredAMS7881B-TEST-REC (Historical)5/6/2020
This specification covers tungsten carbide-cobalt in the form of powder.
AMS F Corrosion Heat Resistant Alloys Committee
Low-Cost Detection of Thin Film Stress During FabricationTBMG-368685/1/2020
NASA’s Marshall Space Flight Center has developed a simple, cost-effective optical method for thin film stress measurements during growth and/or subsequent annealing processes. Stress arising in thin film fabrication presents production challenges for electronic devices, sensors, and optical coatings; it can lead to substrate distortion and deformation, impacting the performance of thin film products.
Tungsten Carbide-Cobalt Chrome Powder Agglomerated and SinteredAMS7882C (Historical)4/21/2020
This specification covers tungsten carbide-cobalt chrome in the form of powder.
AMS F Corrosion Heat Resistant Alloys Committee
Tungsten Carbide-Cobalt Chrome Powder Agglomerated and SinteredAMS7882C-TEST-REC (Historical)4/21/2020
This specification covers tungsten carbide-cobalt chrome in the form of powder.
AMS F Corrosion Heat Resistant Alloys Committee
Development of a Novel Method to Simulate Cavity Preservation in Automotive Industry2020-01-09004/14/2020
Corrosion protection is a major topic of research for automotive manufacturers and major suppliers. The most critical parts affected by corrosion are the pillars and cavities. Automotive manufacturers spend a lot of effort to improve protection layers as much as possible to increase the longevity of their products. The Electro-Coat Paint Operation (ELPO) or E-Coat process is key in achieving this goal. Unfortunately, often the electric current does not reach all the areas very well and resulting in undercoating. Also, the consequent baking process might see the ovens not achieving the desired temperatures into the cavities. As a fact it often happens that these areas are exposed by undercoating, and hence undermining the quality of corrosion protection. Some car manufacturers investigate one level more to assure a good quality of corrosion protection also within cavities, by applying wax. This wax coating process aims to cover all problematic areas in a way to make cavities more
Chitneedi, Bhargav Krishna, Schifko, Martin, Verma, Kevin, Menon, Muraleekrishnan, NAIR, Vishal
Additive Manufacturing Method for Sub-Microscale Three-Dimensional StructuresTBMG-363764/1/2020
NASA Goddard Space Flight Center has developed a substantial advancement in additive manufacturing technology. The method eliminates most material restrictions, enabling fabrication of sub-microscale three-dimensional structures composed of nearly any material that is compatible with chemical vapor deposition (CVD) including metallic and ceramic materials. Current technology for the production of microscale three-dimensional structures, such as two-photon lithography, is generally limited to the use of photosensitive polymeric materials.
Choose Surface Treatments Early to Avoid Future ProblemsTBMG-363854/1/2020
Too often, design engineers look at coating parts as an afterthought. Rather than being part of the discussion in the early stages of design, engineers sometimes try to solve problems with coatings during — or even after — manufacturing. While surface treatments such as anodizing, electroplating, and thermal spray provide their own unique set of properties and benefits, these processes also have limitations that demand attention early in the design process to ensure optimal performance.
Hardening Lightweight Metal Foams with NanocoatingTBMG-358181/1/2020
Bones are strong and stable and can cope with loads almost as well as steel. But despite their strength, they are light enough to be easily moved by humans and animals. The secret lies in the combination of a hard, exterior shell that encases a porous lattice-like network of bone tissue in the interior of the bone. This structure saves on material and reduces weight.
Experimental Study on Tool Wear and Cutting Temperature during Machining of Nimonic C-263 and Waspaloy Based on Taguchi Method and Response Surface Methodology2019-28-014410/11/2019
Nickel based materials of Nimonic C-263 and Waspaloy are used nowadays for aerospace applications owing to its superior strength properties that are maintained at a higher temperature. Tool wear and cutting temperature in the vicinity of cutting edge are two essential machinability characteristics for any cutting tool. In this regard, this study is pursued to examine the influence of factors on measuring of tool wear (Vba) and cutting temperature (Ts) during dry machining of two alloys studied experimentally based on Taguchi method and response surface methodology. Taguchi’s L16 orthogonal array is used to design the experiment and a PVD (TiAlN), CVD (TiN/Al2O3/TiCN) coated carbide inserts are used on turning of two alloys. The factor effect on output responses are studied using analysis of variance, empirical models, and responses surface 3D plots. To minimize the response and to convert into one single optimum level, responses surface desirability function approach is applied. The
Kannan, Vetri Velmurugan, Kannan, Venkatesan, Sundararajan, Devendiran
Optimization of RF Magnetron Sputtering Parameters for Deposition of Zinc Oxide Semiconductor Film at Moderate Temperature of 100°C2019-28-015010/11/2019
Zinc oxide semiconductor thin films are deposited on glass substrate at different RF magnetron sputtering parameters. The deposited films were characterized as a function of substrate - target distance, gas flow ratio, working pressure and RF power. X-ray diffraction, Field emission scanning electron microscopy, and hall measurement were utilized to analyze the effect of the deposition condition on the structure, surface morphology and electrical properties of ZnO thin films. The deposition conditions were optimized to give good quality films suitable for the application of flexible or invisible flat panel display. All the films were deposited at 100°C.
Muthukarappan, Amutha Surabi, Jeyaseelan, Chandradass, Paramathma, Baskara Sethupathi, Park, Seong-Ju
The Challenge of Replacing Hard ChromeTBMG-3535910/1/2019
The search for a suitable replacement for hard chrome on aerospace components has been a key supply chain priority for aircraft manufacturers. This is because of the documented health risks to workers and the impact on the environment from exposure to hexavalent chromium, a carcinogen that occurs during the chrome plating process and is the most toxic form of chromium.
The Challenge of Replacing Hard Chrome19AERP10_0310/1/2019
The search for a suitable replacement for hard chrome on aerospace components has been a key supply chain priority for aircraft manufacturers. This is because of the documented health risks to workers and the impact on the environment from exposure to hexavalent chromium, a carcinogen that occurs during the chrome plating process and is the most toxic form of chromium. As a result, chromium is a highly regulated chemical in major markets worldwide. In the European Union, hexavalent chromium falls under the domain of the EU regulation, REACH (Registration, Evaluation, Authorization and Restriction of Chemicals), which establishes guidelines for the safe use of chemicals throughout the supply chain. Chromium is also closely regulated in the United States by OSHA.
Surface Treatment Could Improve Refrigeration EfficiencyTBMG-351319/1/2019
Unlike water, liquid refrigerants and other fluids that have a low surface tension spread quickly into a sheet when they come into contact with a surface. For many industrial processes, it would be better if the fluids formed droplets that could roll or fall off the surface and carry heat away with them.
Designing Sensors for Hazardous EnvironmentsTBMG-351969/1/2019
Some of the most common applications for hazardous duty sensors are in the oil and gas industry. Rotary encoders are frequently used to provide crucial feedback about moving machinery on the rig. Flammable agents are common in applications near the wellbore, so most electrical components on the rig require special hazardous area certification. Hazardous duty sensors are also used in applications such as paint spray booths because of the volatiles coming off the paint; grain silos because the dust environment is very explosive; chemical factories; explosives factories; and believe it or not, for cosmetics because the very fine powders that are used are highly explosive.
CONNECTOR RECEPTACLE, REVERSE BAYONET COUPLING, DUMMY STOWAGEAS95234/12 (Current)8/27/2019
AE-8C1 Connectors Committee
Aerospace Work Platforms — More than Meets the EyeTBMG-345456/1/2019
For maintenance personnel in the aerospace industry to do their jobs effectively, they need to be able to get physically close to the equipment they are working on. This statement sounds obvious, but in order to meet this requirement, it is very important to utilize quality work platforms. Although most people are familiar with the basic uses of work platforms, there is not always much thought given to everything that goes into their design and fabrication.
Aerospace Work Platforms - More than Meets the Eye19AERP06_136/1/2019
Today's work platforms are far more complex than the simple designs of the past. For maintenance personnel in the aerospace industry to do their jobs effectively, they need to be able to get physically close to the equipment they are working on. This statement sounds obvious, but in order to meet this requirement, it is very important to utilize quality work platforms. Although most people are familiar with the basic uses of work platforms, there is not always much thought given to everything that goes into their design and fabrication. In years past, simple platforms were widely used for a variety of different work applications, however, much more is demanded of them in modern facilities. These increased demands have forced the work platform fabrication industry to evolve. The design and fabrication of today's platforms require manufacturers with expertise, experience, and skill. Fabricators and designers must incorporate specialized features in many areas never before seen or even
Additive manufacturing of titanium alloys by cold spraying onto Al7075F-0075-2019-146295/13/2019
The aluminum alloy Al7075 is commonly used in aircraft industry due to its high mechanical resistance to weight ratio. Nevertheless when the structure is being serviced upon the severe environmental conditions or loads degradation mechanisms could often been found in the material. To improve its behavior the cold spray process with various titanium powders (e.g. CP Ti, Ti-64) deposited onto Al7075 was investigated. The spraying of angular titanium powder was performed in the presence of nitrogen and helium supplied at process parameters (temperature, pressure), which were the maximum values attainable by the CS system used. The deposits were sprayed while maintaining a standoff distance in the range from 20 to 100 mm increased by 10 mm. The experimental data indicated that the deposition efficiency had increased significantly with increasing standoff distance. The coating porosity first decreased to minimum 0.6% and then increased significantly to 9.8%. The mechanical properties of the
Sienicki, Jaroslaw, Żórawski, Wojciech
Army Aviation Additive Repair/Manufacture (AR/M) QualificationF-0075-2019-146245/13/2019
The U.S. Army overhauls aircraft weapon system (AH-64, CH-47, UH-60) and associated components. Significant damage, corrosion, and wear are a main cause of component discrepancies. Typical issues with current fusion weld/thermal spray repair is high distortion and a large heat affected zone (HAZ) to an operational aviation component. These repairs often require large and complex fixtures and processes to stabilize the component during the repair process. The additive repair / manufacture (AR/M) has shown to give a very small HAZ and footprint not requiring the use of complex fixtures. This paper outlines the approach taken to develop and qualify AR/M necessary for airworthiness qualification. Two areas that are researched are laser additive manufacturing (LAM) powder fed systems (or directed energy deposition (DED)) and cold spray additive manufacturing. Establishment of mechanical and metallurgical properties of AR/M are presented. Significant return on investment is being shown using
Cass, Wesley
Enabling Technology for Sustainment of Navy Aircraft StructuresF-0075-2019-146015/13/2019
The Structures Division at the Naval Air Systems Command (NAVAIR) continues to support capital investment in enabling technologies for sustainment of our aircraft which will lower total life cycle costs, ensure safety, and increase operational readiness. This paper presents a general overview of the major improvements which have been made in the area of Structural Health and Usage Management (SHUM), including: usage severity monitoring via regime recognition (RR), gross weight and center of gravity (GW/CG) estimation, local/global damage detection, environmental effects monitoring, damage alleviation, prognostication, and individual asset/component tracking (IAT). Advances in structural analyses have been made in the accuracy of predicted rotorcraft loads using coupled rotor and fuselage interactions. Innovative approaches to fatigue testing at both the component and full scale airframe levels will allow for more accurate introduction of vibratory loading content from operation, reveal
Semidey, Roberto, Glucksman-Glaser, Mark, Phan, Nam
Functional PVD Coatings Improve Medical Device Performance and LifeTBMG-344345/1/2019
As the medical device industry continues to grow rapidly, manufacturers must contend with a variety of challenges if they wish to differentiate products in a highly competitive market. With this in mind, greater emphasis is being placed on the functional coatings that are applied to stainless steel, titanium, and other substrates of critical medical devices from implants to scalpels, needle drivers, bone saws, and reamers.
LED Lighting Improves Efficiency and ImagingTBMG-343975/1/2019
Rocket engine testing requires a lot of light since all tests are filmed with high-speed cameras to monitor performance; however, those cameras have to adjust to the bright plume from a firing engine, which would black out the rest of the image. Traditionally, that light has been provided by metal halide bulbs.
Experimental Study on Impingement of Fuel Droplet on Substrates2019-01-03004/2/2019
Within a gasoline direct injection (GDI) engine, the impingement of fuel droplet on substrates induces various problems such as particular matter emission, oil dilution and abnormal combustion. Therefore, in order to solve these problems, it is urgent to have a clear understanding of the impingement behavior of fuel droplet impacting on substrates. Most previous studies have focused on the impingement of either water droplet on dry solid surface or the impinging droplet on the liquid film of the same type of liquid, while little research has been conducted on the impingement of fuel droplet on relevant substrates existing in GDI engines. The impingement of fuel droplet with higher Weber number on dry surface, fuel film and oil film with different thickness and viscosity were investigated experimentally. Results show that fuel droplet impacting on dry wall is easy to be deposited to form a fuel film. The fuel film attached to the wall is the main reason for the splash. The thickness of
Peng, Zhenshan, Pei, Yiqiang, Qin, Jing, Lu, Lili, Zhu, Qingyang
New 3D Printing Process for Bone ImplantsTBMG-342634/1/2019
Researchers have developed a technique with which bone implants that are precisely fitting, stable, and variable in dimensions can be 3D printed from a special plastic. In the printing process, individual layers are treated with a cold plasma in order to improve the bonding of bone-forming cells.
Enhancing Electrode Properties with Laser RestructuringTBMG-342654/1/2019
The materials that go into medical devices — particularly implantable electrical devices — have to strike a unique balance of properties. Once you consider biocompatibility and all the required physical and mechanical properties, there are very few metals that will make the grade. In fact, for electrode materials, you won't get much further than platinum and gold. And while innovative new alloys do occasionally emerge, there are usually limited opportunities to solve engineering problems by turning to entirely new materials.
Fabric Alternative to Batteries for Wearable DevicesTBMG-341484/1/2019
Wearable biosensors for health monitoring lack a lightweight, long-lasting power supply. A new method was developed for making a charge-storing system that is easily integrated into clothing for embroidering a charge-storing pattern onto any garment.
Scalable Manufacturing Process for Creating Spools of GrapheneTBMG-336952/1/2019
For many researchers, graphene is ideal for use in filtration membranes. A single sheet of graphene resembles atomically thin chicken wire, and is composed of carbon atoms joined in a pattern that makes the material extremely tough and impervious to even the smallest atom: helium.
Does Your Coating System Require Climate Control? What to Look For and What to ExpectTBMG-3342212/1/2018
There is one aspect of the paint and coatings finishing business virtually guaranteed to give the budget director heart failure: climate control. There's no way around it – climate control systems are expensive.
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