Chromium-Free Corrosion-Resistant Hybrid UV Coatings

EPA Contract Number: EPD09029
Title: Chromium-Free Corrosion-Resistant Hybrid UV Coatings
Investigators: Curatolo, Ben
Small Business: Light Curable Coatings
EPA Contact: Richards, April
Phase: I
Project Period: February 1, 2009 through July 31, 2009
Project Amount: $69,997
RFA: Small Business Innovation Research (SBIR) - Phase I (2009) RFA Text |  Recipients Lists
Research Category: SBIR - Pollution Prevention , Small Business Innovation Research (SBIR)


This SBIR Phase I project is designed to determine the feasibility of preparing an environmentally friendly chromium-free solvent-free hybrid ultraviolet (UV) resin coating system suitable for applications such as industrial, automotive, and aerospace corrosion resistance. In particular, the overall objective of this program is to determine the most appropriate segregation of components for a two part chromium-free corrosion-resistant hybrid UV coating system, an appropriate corrosion inhibitor charge level, and an appropriate ratio of reactive rate of cure in the absence of UV light to dry material in shadow areas where the coating may not be exposed to sufficient UV energy for typical UV cure. The hybrid UV resin coating system will be characterized with respect to UV cure rate, secondary cure rate, adhesion, surface hardness, and corrosion resistance. 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 is designed to demonstrate feasibility and to provide sufficient groundwork for Phase II development of the technology. Phase II will involve the preparation and characterization of fully formulated hybrid resin systems, incorporating pigments and other important components for appropriate color and gloss and to satisfy important property requirements of aerospace primer specification MIL-PRF-23377 and aerospace topcoat specification MIL-PRF-85285. Light Curable Coatings is a technology leader of solvent-free environmentally compliant coating systems, with 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. Since this hybrid resin system contains safer components, application in confined spaces 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 vehicles by reducing environmental risks associated with maintenance, storage, and disposal. This research offers a significant positive societal impact in terms of a better quality of life for industrial workers an for all citizens through safer workplaces and a cleaner environment.

Supplemental Keywords:

small business, SBIR, EPA, chromium, corrosion-resistant, corrosion-resistant coating, chromium free, chromium alternative, hybrid UV coating, solvent-free, UV resin coating system, industry, automotive, aerospace, corrosion inhibitor charge level, reactive rate of cure, UV cure, cure rate, adhesion, hardness, exposure, hexavalent chromium, volatile organic compounds, VOCs, hazardous air pollutants, HAPs, hybrid resin system, primer specification, topcoat specification, environmental risk, industrial workers, light curable coating,

Progress and Final Reports:

  • Final Report
  • SBIR Phase II:

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