{"id":8251,"date":"2018-06-15T08:00:32","date_gmt":"2018-06-15T14:00:32","guid":{"rendered":"https:\/\/www.ulprospector.com\/knowledge\/?p=8251"},"modified":"2018-06-22T08:44:02","modified_gmt":"2018-06-22T14:44:02","slug":"pc-aerospace-coatings","status":"publish","type":"post","link":"https:\/\/ulprospector.ul.com\/8251\/pc-aerospace-coatings\/","title":{"rendered":"Take Flight with Exterior Aerospace Coatings"},"content":{"rendered":"<p><img loading=\"lazy\" decoding=\"async\" class=\"alignright size-full wp-image-8335\" src=\"https:\/\/ulprospector.ul.com\/media\/2018\/06\/pc-airplane-innsbruck-106723_600x400.jpg\" alt=\"Read about the challenges of formulating aerospace exterior coatings in the Prospector Knowledge Center.\" width=\"600\" height=\"400\" srcset=\"https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2018\/06\/pc-airplane-innsbruck-106723_600x400.jpg 600w, https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2018\/06\/pc-airplane-innsbruck-106723_600x400-300x200.jpg 300w\" sizes=\"(max-width: 600px) 100vw, 600px\" \/>Aerospace coatings for exterior applications require a demanding set of <strong><em>performance attributes<\/em><\/strong> to provide acceptable performance from both a functional and aesthetic standpoint. In many cases the cost of a new commercial aircraft can be over $300 million with the expectation of lasting several decades with flight times of 4,000 hours or more on an annual basis. According to GMI, the aerospace coating market size is estimated to surpass $1 Billion in sales by 2024.<\/p>\n<p>Aerospace coating requirements can include:<\/p>\n<ul>\n<li>Ability to maintain adhesion and flexibility when subject to rapid temperature changes from 120F to \u2013 70F in a matter of a few minutes<\/li>\n<li>Resistance to hydraulic fluids including Skydrol, diesel fuel, lubricating oils and deicing fluids<\/li>\n<li>Resist degradation when exposed to intense UV light at high altitudes<\/li>\n<li>Repeated dry hot and cold moist cycles<\/li>\n<li>Outstanding corrosion resistance as aircraft are often operated in marine and industrial environments<\/li>\n<li>High degree of flexibility and resistance to stress as a result of turbulence, vibration and wing flexing<\/li>\n<li>Abrasion and erosion resistance and paint from dirt and sand at sub and supersonic speeds<\/li>\n<li>Infrared (IR) reflectivity (military applications)<\/li>\n<li>Low density (offers weight savings)<\/li>\n<li>Icephobic<\/li>\n<li>Low COF<\/li>\n<\/ul>\n<hr \/>\n<h3>Looking for materials for aerospace coatings formulations?<\/h3>\n<p>UL Prospector\u00ae has nearly 100 listings for resins, pigments, adhesives, and base formulations for use in aerospace coatings. Get technical data, request samples, and contact suppliers now.<\/p>\n<h3><a href=\"https:\/\/www.ulprospector.com\/en\/na\/Coatings\/search?k=aerospace&amp;st=31\" target=\"_blank\" rel=\"noopener\">Search aerospace coatings materials<\/a><\/h3>\n<hr \/>\n<p>The <strong><em>substrate<\/em><\/strong> for the fuselage and aircraft skin is predominantly AA 2024 aluminum. AA 2024 is an alloy of copper and aluminum. The copper provides an increase in the strength to weight relationship, however it is also detrimental to corrosion resistance. Weight reduction is an enormous driving force in new aircraft design as it equates to fuel savings, speed and range. Composites, fiber metal laminates and aluminum-lithium alloys are being used on an increasing basis.<\/p>\n<p>A number of <strong><em>cleaning\/pretreatment types<\/em><\/strong> (historically hexavalent chrome-based) provide a thin protective layer to improve corrosion resistance as well as receptivity of subsequent coats as it increases surface tension and polarity of the surface.<\/p>\n<ul>\n<li><strong><em>Organic Coatings<\/em><\/strong> typically include a primer, pigmented basecoat and a clearcoat.<\/li>\n<li><strong><em>Primers<\/em><\/strong> are typically organic solventborne and waterborne two-component epoxy-polyamine\/polyamide types containing extenders, additives, catalysts and are further fortified with corrosion inhibitive pigments.<\/li>\n<\/ul>\n<p>Common types of <strong><em>corrosion<\/em><\/strong> on aircraft include <strong><em>filiform<\/em><\/strong>, <strong><em>pitting, intergranular, exfoliation, stress cracking, galvanic <\/em><\/strong>and <strong><em>crevice corrosion. <\/em><\/strong>All these types of corrosion are exacerbated by moisture, salt, thermocycling and direct contact of metals differing in metallic content.<\/p>\n<p>Common corrosion inhibitive pigments historically used in aerospace primers include barium chromate and strontium chromate. Epoxy resins for the most part are combinations of bisphenol A and bisphenol F types. When formulated with suitable crosslinking agents (normally amine or amido-amine type) epoxy-based primers provide excellent adhesion, corrosion resistance and chemical resistance.<\/p>\n<figure id=\"attachment_8312\" class=\"thumbnail wp-caption aligncenter\" style=\"width: 783px\"><img loading=\"lazy\" decoding=\"async\" class=\"size-full wp-image-8312\" src=\"https:\/\/ulprospector.ul.com\/media\/2018\/05\/filiform-corrosion.png\" alt=\"Filiform Corrosion on Coated Aluminum - learn about exterior aerospace coatings in the Prospector Knowledge Center.\" width=\"783\" height=\"325\" srcset=\"https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2018\/05\/filiform-corrosion.png 783w, https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2018\/05\/filiform-corrosion-300x125.png 300w, https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2018\/05\/filiform-corrosion-768x319.png 768w\" sizes=\"(max-width: 783px) 100vw, 783px\" \/><figcaption class=\"caption wp-caption-text\">Figure 1. Images of Filiform Corrosion on Coated Aluminum<\/figcaption><\/figure>\n<figure id=\"attachment_8313\" class=\"thumbnail wp-caption aligncenter\" style=\"width: 862px\"><img loading=\"lazy\" decoding=\"async\" class=\"size-full wp-image-8313\" src=\"https:\/\/ulprospector.ul.com\/media\/2018\/05\/aerospace-coatings-cross-section.png\" alt=\"Cross-section of Aerospace Coating Layers - learn about exterior aerospace coatings in the Prospector Knowledge Center.\" width=\"862\" height=\"333\" srcset=\"https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2018\/05\/aerospace-coatings-cross-section.png 862w, https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2018\/05\/aerospace-coatings-cross-section-300x116.png 300w, https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2018\/05\/aerospace-coatings-cross-section-768x297.png 768w\" sizes=\"(max-width: 862px) 100vw, 862px\" \/><figcaption class=\"caption wp-caption-text\">Figure 1a. Cross-section of Aerospace Coating Layers<\/figcaption><\/figure>\n<p>&nbsp;<\/p>\n<figure id=\"attachment_8334\" class=\"thumbnail wp-caption aligncenter\" style=\"width: 814px\"><img loading=\"lazy\" decoding=\"async\" class=\"size-full wp-image-8334\" src=\"https:\/\/ulprospector.ul.com\/media\/2018\/06\/areospace-primer-resins.jpg\" alt=\"Typical epoxy resins and epoxy functional reactive diluents used in aerospace primers. Learn more about aerospace exterior coatings in the Prospector Knowledge Center.\" width=\"814\" height=\"631\" srcset=\"https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2018\/06\/areospace-primer-resins.jpg 814w, https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2018\/06\/areospace-primer-resins-300x233.jpg 300w, https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2018\/06\/areospace-primer-resins-768x595.jpg 768w\" sizes=\"(max-width: 814px) 100vw, 814px\" \/><figcaption class=\"caption wp-caption-text\">Figure 2. Typical epoxy resins and epoxy functional reactive diluents used in aerospace primers<\/figcaption><\/figure>\n<p>&nbsp;<\/p>\n<figure id=\"attachment_8314\" class=\"thumbnail wp-caption aligncenter\" style=\"width: 664px\"><img loading=\"lazy\" decoding=\"async\" class=\"size-full wp-image-8314\" src=\"https:\/\/ulprospector.ul.com\/media\/2018\/05\/aerospace-epoxy-resin-reactions.png\" alt=\"Reactions of epoxy resins with amino functionalities - learn about exterior aerospace coatings in the Prospector Knowledge Center.\" width=\"664\" height=\"449\" srcset=\"https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2018\/05\/aerospace-epoxy-resin-reactions.png 664w, https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2018\/05\/aerospace-epoxy-resin-reactions-300x203.png 300w\" sizes=\"(max-width: 664px) 100vw, 664px\" \/><figcaption class=\"caption wp-caption-text\">Figure 3 Reactions of epoxy resins with amino functionalities<\/figcaption><\/figure>\n<p><strong><em>Aerospace exterior topcoats<\/em><\/strong> are two-component urethane types comprised of hydroxyl functional resins [polyesters, acrylics or fluorinated ethylene vinyl ethers (FEVE)] reacted with isocyanate prepolymer(s). Typical curing reactions are as follow:<\/p>\n<figure id=\"attachment_8315\" class=\"thumbnail wp-caption aligncenter\" style=\"width: 706px\"><img loading=\"lazy\" decoding=\"async\" class=\"size-full wp-image-8315\" src=\"https:\/\/ulprospector.ul.com\/media\/2018\/05\/aerospace-polyol-reactions.png\" alt=\"Reactions of polyols with isocyanate functional cross-linkers - learn about exterior aerospace coatings in the Prospector Knowledge Center.\" width=\"706\" height=\"458\" srcset=\"https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2018\/05\/aerospace-polyol-reactions.png 706w, https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2018\/05\/aerospace-polyol-reactions-300x195.png 300w\" sizes=\"(max-width: 706px) 100vw, 706px\" \/><figcaption class=\"caption wp-caption-text\">Figure 4 Reactions of polyols with isocyanate functional cross-linkers<\/figcaption><\/figure>\n<p>Due to the demanding requirements of aerospace coating systems, chemists use a stoicheometric excess of isocyanate crosslinker to provide excellent chemical resistance. The excess isocyanate crosslinker reacts with moisture to decarboxylate to form a polyurea upon further reaction. Typically a 50 percent or more stoichiometric excess of isocyanate is used to ensure a high degree of polyurea formation.<\/p>\n<p>Polyureas are known for their superb resistance to aggressive fluids such as Skydrol (an aircraft hydraulic fluid).<a href=\"https:\/\/www.ulprospector.com\/en\/na\/Coatings\/search?k=Polyester+polyol&amp;st=31\" target=\"_blank\" rel=\"noopener\"> <strong><em>Polyester polyols<\/em><\/strong> <\/a>are used primarily in the pigmented basecoat portion of the two component polyurethane coating, whereas <a href=\"https:\/\/www.ulprospector.com\/en\/na\/Coatings\/search?k=acrylic+polyol&amp;st=31\" target=\"_blank\" rel=\"noopener\"><strong><em>acrylic polyols<\/em><\/strong><\/a> and also <strong><em>FEVE-based polyols<\/em><\/strong> are primarily used in the clearcoat portion of the polyurethane topcoat.<\/p>\n<p>Clearcoats are further fortified with both UV absorbers as well as hindered amine light stabilizers to further protect the coating system from degradation due to exposure to intense upper atmosphere UV light.<\/p>\n<p><a href=\"https:\/\/www.ulprospector.com\/en\/na\/Coatings\/search?k=Isocyanate+crosslinker&amp;st=31\" target=\"_blank\" rel=\"noopener\"><strong><em>Isocyanate crosslinkers<\/em><\/strong><\/a> are typically derived from hexmethylene diisocyante (HMDI) and\/or isophorone isocyanate (IPDI). The former type provides flexibility, whereas the latter can provide improved hardness.<\/p>\n<figure id=\"attachment_8316\" class=\"thumbnail wp-caption aligncenter\" style=\"width: 1012px\"><img loading=\"lazy\" decoding=\"async\" class=\"size-full wp-image-8316\" src=\"https:\/\/ulprospector.ul.com\/media\/2018\/05\/aerospace-biuret.png\" alt=\"Biuret formed from the reaction of three HMDI molecules - learn about exterior aerospace coatings in the Prospector Knowledge Center.\" width=\"1012\" height=\"272\" srcset=\"https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2018\/05\/aerospace-biuret.png 1012w, https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2018\/05\/aerospace-biuret-300x81.png 300w, https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2018\/05\/aerospace-biuret-768x206.png 768w\" sizes=\"(max-width: 1012px) 100vw, 1012px\" \/><figcaption class=\"caption wp-caption-text\">Figure 5 Biuret formed from the reaction of three HMDI molecules<\/figcaption><\/figure>\n<figure id=\"attachment_8317\" class=\"thumbnail wp-caption aligncenter\" style=\"width: 1012px\"><img loading=\"lazy\" decoding=\"async\" class=\"size-full wp-image-8317\" src=\"https:\/\/ulprospector.ul.com\/media\/2018\/05\/aerospace-Isocyanurate.png\" alt=\"Isocyanurate formed from the reaction of three HMDI molecules - Prospector Knowledge Center\" width=\"1012\" height=\"306\" srcset=\"https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2018\/05\/aerospace-Isocyanurate.png 1012w, https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2018\/05\/aerospace-Isocyanurate-300x91.png 300w, https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2018\/05\/aerospace-Isocyanurate-768x232.png 768w\" sizes=\"(max-width: 1012px) 100vw, 1012px\" \/><figcaption class=\"caption wp-caption-text\">Figure 6 Isocyanurate formed from the reaction of three HMDI molecules<\/figcaption><\/figure>\n<figure id=\"attachment_8318\" class=\"thumbnail wp-caption aligncenter\" style=\"width: 1012px\"><img loading=\"lazy\" decoding=\"async\" class=\"size-full wp-image-8318\" src=\"https:\/\/ulprospector.ul.com\/media\/2018\/05\/aerospace-Uretdione.png\" alt=\"Uretdione formed from two HMDI molecules, as used in exterior aerospace coatings\" width=\"1012\" height=\"235\" srcset=\"https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2018\/05\/aerospace-Uretdione.png 1012w, https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2018\/05\/aerospace-Uretdione-300x70.png 300w, https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2018\/05\/aerospace-Uretdione-768x178.png 768w\" sizes=\"(max-width: 1012px) 100vw, 1012px\" \/><figcaption class=\"caption wp-caption-text\">Figure 7 Uretdione formed from two HMDI molecules<\/figcaption><\/figure>\n<figure id=\"attachment_8319\" class=\"thumbnail wp-caption aligncenter\" style=\"width: 1012px\"><img loading=\"lazy\" decoding=\"async\" class=\"size-full wp-image-8319\" src=\"https:\/\/ulprospector.ul.com\/media\/2018\/06\/aerospace-Isophorone-Diisocyanate.png\" alt=\"Isophorone Diisocyanate - learn about its use in exterior aerospace coatings in the Prospector Knowledge Center\" width=\"1012\" height=\"293\" srcset=\"https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2018\/06\/aerospace-Isophorone-Diisocyanate.png 1012w, https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2018\/06\/aerospace-Isophorone-Diisocyanate-300x87.png 300w, https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2018\/06\/aerospace-Isophorone-Diisocyanate-768x222.png 768w\" sizes=\"(max-width: 1012px) 100vw, 1012px\" \/><figcaption class=\"caption wp-caption-text\">Figure 8 Isophorone Diisocyanate<\/figcaption><\/figure>\n<p><strong><em>Isocyanurate<\/em><\/strong>-based isocyanate cross linkers provide excellent weathering characteristics when reacted with a suitable polyol resin system and are thus widely used in aerospace topcoats.<\/p>\n<p><strong><em>Recent innovations and project emphasis<\/em><\/strong> in aerospace coatings include chrome-free pretreatment-primers and chrome-free epoxy primers. Drag-reducing topcoats that provide a 1 percent improvement in fuel efficiency can lower fuel costs by $700 million a year, according to the International Air Transport Association (IATA). On average, airlines incur about $100 a minute per flight in total operating costs, IATA says. Therefore, even saving just one minute of flight time could reduce total industry operating costs by more than $1 billion a year and significantly reduce environmental emissions.<\/p>\n<h3>Further Reading:<\/h3>\n<ul>\n<li><a href=\"https:\/\/ulprospector.ul.com\/8168\/pc-aluminum-cleaning-passivation-corrosion-protection-monitoring?st=31\" target=\"_blank\" rel=\"noopener\">As the Wheel Turns: Aluminum Cleaning, Passivation, Corrosion Protection and Monitoring<\/a><\/li>\n<li><a href=\"https:\/\/ulprospector.ul.com\/3152\/pc-fundamentals-corrosion-protection?st=31\" target=\"_blank\" rel=\"noopener\">Fundamentals of Corrosion Protection<\/a><\/li>\n<li><a href=\"https:\/\/ulprospector.ul.com\/744\/pc-corrosion-inhibitive-pigments?st=31\" target=\"_blank\" rel=\"noopener\">Understanding Corrosion Inhibitive Pigments<\/a><\/li>\n<li><a href=\"https:\/\/ulprospector.ul.com\/7354\/pc-chemistry-of-resins-and-hardeners?st=31\" target=\"_blank\" rel=\"noopener\">Chemistry of Resins and Hardeners<\/a><\/li>\n<\/ul>\n<h3>References:<\/h3>\n<ul>\n<li>Active Protective Coatings, Springer et.al., 2016<\/li>\n<li>Organic Coatings Science and Technology, 3<sup>rd<\/sup> Edition, Wicks et.al, 2007<\/li>\n<\/ul>\n","protected":false},"excerpt":{"rendered":"<p>Aerospace coatings for exterior applications require a demanding set of performance attributes to provide acceptable performance from both a functional and aesthetic standpoint. In many cases the cost of a new commercial aircraft can be over $300 million with the &hellip; <a href=\"https:\/\/ulprospector.ul.com\/8251\/pc-aerospace-coatings\/\">Continued<\/a><\/p>\n","protected":false},"author":12,"featured_media":8335,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0,"episode_type":"","audio_file":"","podmotor_file_id":"","podmotor_episode_id":"","cover_image":"","cover_image_id":"","duration":"","filesize":"","filesize_raw":"","date_recorded":"","explicit":"","block":"","itunes_episode_number":"","itunes_title":"","itunes_season_number":"","itunes_episode_type":"","footnotes":""},"categories":[16],"tags":[219],"ppma_author":[1249],"class_list":{"0":"post-8251","1":"post","2":"type-post","3":"status-publish","4":"format-standard","5":"has-post-thumbnail","7":"category-paint-coatings","8":"tag-category-overview","9":"entry"},"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.3 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Exterior aerospace coatings: Formulation challenges &amp; considerations<\/title>\n<meta name=\"description\" content=\"Exterior aerospace coatings demand specific performance attributes. 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Lewarchik, President and CEO of Chemical Dynamics, LLC, brings 40 years of paint and coatings industry expertise to his role as a contributing author with the Prospector Knowledge Center. As a contributing writer, Ron pens articles on topics relevant to formulators in the coatings industry. He also serves as a consultant for the Prospector materials search engine, advising on issues related to optimization and organization materials within the database. Ron's company, Chemical Dynamics, LLC (www.chemicaldynamics.net), is a full-service paint and coatings firm specializing in consulting and product development based in Plymouth, Michigan. Since 2004, he has provided consulting, product development, contract research, feasibility studies, failure mode analysis and more for a wide range of clients, as well as their suppliers, customers and coaters. He has also served as an Adjunct Research Professor at the Coatings Research Institute of Eastern Michigan University. 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