Reusable launch vehicles located by the ocean are subject to harsh seacoast environments before launch and immersion after splashdown at sea and towback to the refurbishment facility. High strength aluminum and non-corrosion resistant steel alloys are prone to general corrosion and pitting due to galvanic couples and protective coating damage. Additional protection of structural materials with thermally sprayed pure aluminum coatings was evaluated for plasma, arc spray and high velocity oxy-fuel (HVOF) processes. Comparisons are made for corrosion rates of various coated aluminum alloy and steel substrates when exposed to ASTM B-117 neutral salt fog testing and also to beach exposure tests performed at Kennedy Space Center, Florida. Recent development work involved the use of high deposition rate thermal arc-spray equipment. The use of an inverter power supply reduced powdering and enhanced operator visibility. Deposition rates of 45.36 - 68.04 kilograms/hour are obtainable using 4.76 - 6.35 millimeter diameter wire electrodes.

Subject
Zinc rich coatings, Coating application, Materials, Top coats, Substrates, Aluminum spraying, Aluminum, Wiring, High velocity oxy fuel spraying, Plasma, Deposition rate, Arc spraying, Zinc
Keywords:
thermal spray, plasma, arc spray, HVOF, general corrosion, coating adhesion, cathodic protection, aluminum, zinc, Inverter power supply
© 1995 Association for Materials Protection and Performance (AMPP). All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means (electronic, mechanical, photocopying, recording, or otherwise) without the prior written permission of AMPP. Positions and opinions advanced in this work are those of the author(s) and not necessarily those of AMPP. Responsibility for the content of the work lies solely with the author(s).
1995
Association for Materials Protection and Performance (AMPP)
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