Accelerated Manufacturing with Chrome Free Sacrificial Cermet Coatings in Aerospace (AMSCA)

Short Title: AMSCA
Project Number: 101794
Project Cost: £2.33m
End Date: May 31, 2017
Time Horizon: Secure
Lead Partner: Monitor Coatings
Attributes: Environment
ATI Value Stream: Propulsion of the Future

Sacrificial coatings are used in aerospace to protect aircraft against the risk of corrosion by providing a durable seal to individual components. The extra layer prevents the coating of a component from becoming damaged in corrosive environments. All existing sacrificial coatings contain hexavalent chromium Cr6+, which has now been identified as unsafe, and must be replaced by September 2017 to comply with European legislation (REACh).

Although the market currently does offer some alternatives, these substitutes do not provide required performance, therefore new replacement materials need to be researched, tested and produced – a total of eight partners have come together to address this issue.

This ATI funded project, led by Monitor Coatings Limited, aims to formulate a new sacrificial coating for corrosion protection of steel aero-engine components – one that is free from hexavalent chromium. The AMSCA project team aims to demonstrate the technology to TRL5 (technology readiness level 5 – component and/or breadboard validation in relevant environment) by the time the project completes in May 2017.

The project also provides additional benefits including; the development of improved, cost-effective application methodology, incorporating automation where appropriate, increasing manufacturing rate and capacity and reducing waste. Furthermore, the research carried out during the project will not only be developed through traditional empirical methods (as often the norm in such research), but the project will also aim to provide an improved science based understanding of the coating behaviour – underpinning the innovative sacrificial coating technology being developed.

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