Grantee Research Project Results
Final Report: Pigmented Solvent-Free Corrosion-Resistant UV Coating System
EPA Contract Number: EPD10020Title: Pigmented Solvent-Free Corrosion-Resistant UV Coating System
Investigators: Curatolo, Ben
Small Business: Light Curable Coatings
EPA Contact: Richards, April
Phase: I
Project Period: March 1, 2010 through August 31, 2010
Project Amount: $69,997
RFA: Small Business Innovation Research (SBIR) - Phase I (2010) RFA Text | Recipients Lists
Research Category: Small Business Innovation Research (SBIR) , SBIR - Pollution Prevention
Description:
This research project established the feasibility of preparing an environmentally friendly pigmented chromium-free solvent-free UV light curable coating system in a primary color, suitable for high performance corrosion resistant applications.
This Phase I project demonstrated successful and efficient cure for high performance UV coatings incorporating blue pigment, and also demonstrated that chromium-free corrosion resistance could be provided by this solvent-free UV curable coating system. With appropriate photoinitiator blends, blue pigmented coatings immediately became tack-free and scuff-free upon exposure to UV light. The UV coatings demonstrated good adhesion and pencil hardness values, and also exhibited good solvent resistance.
Incorporation of a chromium-free corrosion inhibitor into a blue multifunctional UV coating was successfully demonstrated, providing a system with immediate cure and excellent corrosion resistance properties. A solvent-free, chromium-free, corrosion-resistant, blue pigmented paint system was prepared for high performance applications such as the protection of aerospace aluminum alloys, with excellent corrosion resistance demonstrated through 1000 hours of ASTM B-117 salt fog testing on scribed 2024-T3 aluminum alloy panels.
An important aspect of this proprietary technology is the potential to significantly reduce exposure of workers and communities to hexavalent chromium, volatile organic compounds (VOCs), and hazardous air pollutant (HAP) materials.
Summary/Accomplishments (Outputs/Outcomes):
The environmentally friendly pigmented chromium-free solvent-free UV light curable coating system was characterized with respect to UV cure rate, adhesion, surface hardness, solvent resistance, and corrosion resistance. The UV coatings demonstrated good adhesion and pencil hardness values, and exhibited good solvent resistance as evidenced by resistance to more than 200 double rubs with methyl ethyl ketone (MEK). The coatings also maintained their integrity and hardness after a 24-hour soak in Skydrol hydraulic fluid.
In this work, the performance of single layer multifunctional blue solvent-free chromium-free corrosion-resistant coatings was superior to the performance of two-layer coating systems comprised of white primers and blue topcoats. Single layer blue multifunctional UV coatings provided excellent corrosion resistance through 1000 hours of ASTM B-117 salt fog testing on scribed 2024-T3 aluminum alloy panels, with shiny scribe lines and no blisters, salting, or corrosion of any kind.
Conclusions:
This Phase I SBIR project demonstrated the feasibility of preparing an environmentally friendly pigmented chromium-free solvent-free UV light curable coating system in a primary color, suitable for high performance corrosion resistant applications. Successful cure was demonstrated for high performance UV coatings incorporating blue pigment, and excellent corrosion resistance was demonstrated by incorporating a chromium-free corrosion inhibitor into blue multifunctional UV coatings. With the environmental and performance advantages of UV curing, this high performance coating technology is suitable for numerous industrial, automotive, and aerospace applications requiring corrosion protection.
Demonstration of the feasibility of this environmentally friendly pigmented chromium-free solvent-free UV light-curable coating system in a primary color, suitable for high performance corrosion resistant applications, provided the basis for further research and characterization for the technology, including a more complete evaluation according to the major appearance and physical property requirements of aerospace primer specification MIL-PRF-23377 and aerospace topcoat specification MIL-PRF-85285. Demonstration of the feasibility of this technology also allows for the extension of the technology to other primary colors as a basis for a complete complement of colors desirable for a full tint line and for applicability to a wider range of commercial applications.
Commercialization:
Potential commercial applications of the environmentally friendly chromium-free solvent-free primary color UV light curable coating technology include industrial, automotive, and aerospace coatings for corrosion protection. Anticipated benefits of this technology include improved environmental friendliness, efficiency, and productivity capabilities. Because this coating 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 and industrial products by reducing environmental risks associated with maintenance, storage, and disposal. This technology offers a significant positive societal impact in terms of a better quality of life for industrial workers and for citizens through safer workplaces and a cleaner environment.
Supplemental Keywords:
small business, SBIR, EPA, manufacturing, workplace, environment, ultraviolet coating system, UV, hazardous air pollutant, HAP, corrosion resistance, photoinitiator components, industrial workers, toxic components, corrosion-resistant coating, pollution prevention, chromium-free coating
The perspectives, information and conclusions conveyed in research project abstracts, progress reports, final reports, journal abstracts and journal publications convey the viewpoints of the principal investigator and may not represent the views and policies of ORD and EPA. Conclusions drawn by the principal investigators have not been reviewed by the Agency.