Chromium-Free Corrosion-Resistant Hybrid UV Coatings

EPA Contract Number: EPD10057
Title: Chromium-Free Corrosion-Resistant Hybrid UV Coatings
Investigators: Curatolo, Ben
Small Business: Dr. Ben Curatolo, Inc. d.b.a. Light Curable Coatings
EPA Contact: Manager, SBIR Program
Phase: II
Project Period: May 1, 2010 through April 30, 2012
Project Amount: $224,998
RFA: Small Business Innovation Research (SBIR) - Phase II (2010) Recipients Lists
Research Category: Small Business Innovation Research (SBIR) , SBIR - Pollution Prevention

Description:

This SBIR Phase II project is designed to develop and optimize a prototype environmentally friendly, chromium-free, corrosion-resistant, hybrid ultraviolet (UV) coating system with demonstrated properties suitable for industrial, automotive, and aerospace corrosion protection. The objectives of this Phase II project include the optimization of individual formulation components in the development of a fully formulated system suitable for a more complete evaluation according to the major appearance and physical property requirements of aerospace primer specification MIL-PRD-23377 and aerospace topcoat specification MIL-PRE-85285. A commercial objective of this work is the development of a product that meets design specifications for aerospace primer or combined primer/topcoat without requiring the use of a hazardous component such as hexavalent chromium. This proprietary hybrid UV coating system provides immediate cure when exposed to UV light along with a secondary cure mechanism. It has a suitable rate of cure in the absence of UV light to dry overspray to reduce the possibility of contamination from spray painting operations and to dry material in shadow areas where the coating may not be exposed to sufficient UV energy for typical UV cure. An important aspect of this technology is to significantly reduce exposure of workers and communities to hexavalent chromium, volatile organic compounds (VOCs), and hazardous air pollutant (HAP) materials. Phase I research demonstrated feasibility and provided sufficient groundwork for Phase II development of the technology. Light Curable Coatings is a technology leader for solvent-free environmentally compliant coating systems, which include proprietary technology for rapidly cured heavily pigmented coatings with UV light, including low gloss camouflage color UV coating systems. The described chromium-free corrosion-resistant hybrid UV coating system is proprietary to Light Curable Coatings.

Anticipated benefits of the proposed approach include dramatically improved environmental friendliness, economics, and productivity capabilities. Because this hybrid resin system contains safer components, application in confined and occupied spaces should be possible without the hazards presented by conventional materials. Environmental savings apply not only in production, but also throughout and beyond the operational lifecycle of industrial parts and vehicles by reducing environmental risks associated with maintenance, storage, and disposal. This research offers a significant positive societal impact in terms of better quality of life for industrial workers and for citizens through safer workplaces and a cleaner environment.

Supplemental Keywords:

small business, SBIR, EPA, UV coatings, hexavalent chromium, aerospace, primer, top coat, corrosion-resistant, volatile organic compounds, VOCs, hazardous air pollutant, HAP, UV light, hybrid resin, industrial workers, spray painting, light curable coatings, corrosion protection,

Progress and Final Reports:

  • Final Report

  • SBIR Phase I:

    Chromium-Free Corrosion-Resistant Hybrid UV Coatings  | Final Report