Smart Coating for Corrosion Detection and Protection

The Damage Detection System consists of layered composite material made up of two-dimensional thin film damage detection layers separated by thicker, nondetection layers, coupled with a detection system. The damage detection layers within the composite material are thin films with a conductive grid or striped pattern. The conductive pattern can be applied on a variety of substrates using several different application methods. The number of detection layers in the composite material can be tailored depending on the level of damage detection detail needed for a particular application. When damage occurs to any detection layer, a change in the electrical properties of that layer is detected and reported. Multiple damages can be detected simultaneously, providing real-time detail on the depth and location of the damage. The truly unique feature of the System is its flexibility. It can be designed to gather as much (or as little) information as needed for a particular application using wireless communication. Individual detection layers can be turned on or off as necessary, and algorithms can be modified to optimize performance. The damage detection system can be used to generate both diagnostic and prognostic information related to the health of layered composite structures, which will be essential if such systems are utilized to protect human life and/or critical equipment and material.

Powder coatings are used throughout industry to coat a myriad of metallic objects. This method of coating has gained popularity because it conserves materials and eliminates volatile organic compounds. Resins traditionally chosen for powder coatings have low melting points that enable them to melt and flow into a smooth coating before being cured to a durable surface. High-performance resins, such as Teflon, nylon, and polyimide, have not been found suitable for use in powder coatings because of their high melting points. However, KSC's newly developed polyamic acid resins with low melting points can be used in a powder coating. These polyamic acid resins, when sprayed onto metal surfaces, can be cured in conventional powder coating ovens to deliver high-performance polyimide powder coatings. The polyimide powder coatings offer superior heat and electrical stability as well as superior chemical resistance over other types of powder coatings.

In addition to previous LOTUS coating formulations, an additional optical formulation may be applied via vacuum deposition. This coating forms a top layer and may be applied in different thicknesses that serve to enhance its hydrophobic properties. The vacuum deposited material may comprise fluorinated ethylene propylene or a similar material. This coating is transparent and can be used on optical components or any other applications requiring a clear coating.

PCBs have been shown to cause cancer in animals and to have other adverse effects on immune, reproductive, nervous, and endocrine systems. Although the production of PCBs in the United States has been banned since the late 1970s, many surfaces are still coated with PCB-laden paints. The presence of PCBs in paints adds complexity and expense for disposal. Some treatment methods (e.g., use of solvents, physical removal via scraping) are capable of removing PCBs from surfaces, but these technologies create a new waste stream that must be treated. Other methods, like incineration, can destroy the PCBs but destroy the painted structure as well, preventing reuse. To address limitations with traditional abatement methods for PCBs in paints, researchers at NASAs Kennedy Space Center (KSC) and the University of Central Florida have developed the Activated Metal Treatment System (AMTS) for Paints. This innovative technology consists of a solvent solution (e.g., ethanol, d-limonene) that contains an activated zero-valent metal. AMTS is first applied to the painted surface either using spray-on techniques or wipe-on techniques. The solution then extracts the PCBs from the paint. The extracted PCBs react with the microscale activated metal and are degraded into benign by-products. This technology can be applied without removing the paint or dismantling the painted structure. In addition, the surface can be reused following treatment.

Glenn's breakthrough technology introduces batch-fabricated, miniature sensors embedded and distributed over a large surface area of a material or product during the manufacturing process. The sensors can be utilized for test instrumentation or as an integrated in-situ monitoring system. This integrated manufacturing approach preserves the structural and mechanical system integrity by eliminating the antiquated plug-in approach, invasive machining, manual insertion, and gluing processes currently required to implant sensors into a material. The sensor ladder network of resistors and capacitors breaks down as result of the thermo-physical effects caused by temperature, shock, radiation, corrosion, or other reactions, causing a change in the electrical properties. A processor interprets these changes in the electrical properties and generates a high-resolution, large-area surface profile. The profile demonstrates the amount or rate of material deterioration and temperature change, and is used to optimize geometric structural design, develop materials, predict performance, and make decisions. These sensors play an important role as industries work to realize material performance and product design. This type of monitoring is ideal for infrastructures, nuclear enclosures, or any system susceptible to surface deterioration.