2006-2007 - Kennedy Space Center Technology Transfer Office

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High-Performance Polyimide Powder CoatingsMuch of the infrastructure at Kennedy Space Center and other NASA sites has been subjectedCorrosion to outside weathering effects for more than 40 years. Because much of this infrastructure hasControlmetallic surfaces, considerable effort is continually devoted to developing methods to minimizethe effects of corrosion on these surfaces. These efforts are especially intense at KSC, whereoffshore salt spray and exhaust from Solid Rocket Boosters accelerate corrosion. Coatings of varioustypes have traditionally been the choice for minimizing corrosion, and improved corrosion controlmethods are constantly being researched.Recent work at KSC on developing an improved method for repairing Kapton (polyimide)-basedelectrical wire insulation has identified polyimides with much lower melting points than traditionalpolyimides used for insulation. These lower melting points and the many other outstanding physicalproperties of polyimides (thermal stability, chemical resistance, and electrical properties) led us toinvestigate whether they could be used in powder coatings. In Phase 1 of our research, we found thatpolyimides have the potential to perform effectively as coatings. Physical-property testing of panelscoated with an experimental polyimide formulation indicated that the resulting surfaces were hardand durable, with excellent impact resistance, adhesion, and flexibility. Salt fog corrosion testingrevealed that this formulation performed very well on aluminum substrates but exhibited corrosionand lost adhesion on steel panels. All panels coated with this formulation developed, upon baking,a number of small craters or pin holes, randomly distributed across the coated surface, which weconcluded reduced the formulation’s corrosion performance on steel.In Phase 2, we worked toward developing an effective polyimide powder coating resin. Researchbegan with the goal of significantly improving the soak test adhesion and wetting of a polyimidebasedpowder coating. To soak-test the coating in the laboratory, we immersed the coated couponin a 3-percent sodium chloride solution and observed the progress of delamination and corrosionover time. We identified significant improvements in polyimide powder coating resin performancethrough this screen test. The table shows one powder control and six polyimide formulations tested.Items 5 through 7 showed improved adhesion over the controls, and Item 2 was the best formulationidentified through Phase 1 research.A 1,000-hr salt fog test of Items 5 through 7 revealed significant corrosion resistance over the Phase 1polyimide formula. Figures 1 and 2 highlight this improvement.Results of adhesion and wetting tests.Item Formulation Adhesion Wetting Comments1 DuPont Clear Epoxy 3.5 5.02 Phase 1 Polyimide Formula 2.0 4.5 Phase 1 Salt FogDelamination begins > 14 days3 Phase 2 Polyimide Resin A 5.0 3.04 Phase 2 Polyimide Crosslinker 1.0 4.05 3/4/Epoxy resin/PL 545(8:1:0.7:0.3)w6 3/4/PL 545 (9:0.7:0.3)w3/polyester resin/PL 5455.0 4.5 “Formula 1”5.0 4.5 “Formula 2,” all polyimide7 (9.2:0.5:0.3)w 4.5 4.5 “Formula 3”; no methylacrylic acid (MAA)0: Very poor; 5: Excellent PL 545: flow/leveling aidSpaceport Structures and Materials
Close examination of the corrosionspots on steel panels, shown inFigure 2, revealed that thesecorrosion spots began where smallcraters existed after coating. Nocorrosion was found where thesecraters were not present. Nocorrosion was noted on aluminum,even with the presence of smallcraters.In conclusion, this researchdeveloped polyimide resins with goodmelt properties suitable for coatings.The results of a 1,000-hr salt fog testfor 1-mil polyimide on steel coatingswere encouraging, and excellentsalt fog results were achieved onaluminum panels. This noveltechnology led to the submission oftwo NASA New Technology Reports.Figure 1. Steel, Item 4, Phase 1: 525-hour salt fog test.Contacts: Dr. Luz Marina Calle, NASA-KSC,(321) 867-3278; and Dr. David Trejo, Texas A&MUniversity, (979) 845-2416Participating Organizations: ASRCAerospace (Dr. Scott T. Jolley and LillianaFitzpatrick) and University of CentralFlorida (Dr. Mary C. Whitten)Figure 2. Steel, Item 7, Phase 2: 1,000-hour salt fog test.Figure 3. Aluminum, Item 4, Phase 2: 1,000-hour salt fog test.KSC Technology Development and Application 2006-2007
Page 5 and 6: ForewordSuccessful technology devel
Page 7 and 8: ContentsSpaceport Structures and Ma
Page 9 and 10: Contents (continued)Process and Hum
Page 11 and 12: IntroductionJohn F. Kennedy Space C
Page 13 and 14: Constellation SystemsSurfaceSystems
Page 15 and 16: Spaceport Structures and MaterialsK
Page 17 and 18: 20181614∆ E1210Modified Sensor Be
Page 19 and 20: Initial results of the EDEM model o
Page 21: Contacts: Dr. Carlos I. Calle ,NASA
Page 25 and 26: Adhesion at Failure (psi)2500200015
Page 27 and 28: Figure 1. After 500 hours of salt f
Page 29 and 30: Contacts: Dr. Paul E. Hintze , NASA
Page 31 and 32: Figure 2. Repairs to various types
Page 33 and 34: on top of the cuvette contains the
Page 35 and 36: Figure 2. A corrugated NiTi sheet e
Page 37 and 38: The PLTD can be used to (1) calibra
Page 39 and 40: SEM images of neat MWNT fibers: (a)
Page 41 and 42: Contacts: Trent M. Smith
Page 43 and 44: Figure 1. An isometric cutaway view
Page 45 and 46: Figure 2. Quartz sand flowing in th
Page 47 and 48: Figure 2. Top images show how the e
Page 49 and 50: Sand volume fraction contour at t =
Page 51 and 52: Integrated LWRD/RVC engineering bre
Page 53 and 54: Mean relative percentage change in
Page 55 and 56: We compared the model’s predictio
Page 57 and 58: Figure 2. Three-dimensional simulat
Page 59 and 60: Figure 3. Camera calibration model.
Page 61 and 62: The sketch in Figure 2 shows alaunc
Page 63: Figure 2. Signal generator (right)
Page 66 and 67: Hail Size Distribution MappingA 3-D
Page 68 and 69: Launch Pad 39 Hail Monitor Array Sy
Page 70 and 71: Autonomous Flight Safety System - P
Page 72 and 73:
The Photogrammetry CubeSpaceport/Ra
Page 74 and 75:
Bird Vision SystemThe Bird Vision s
Page 76 and 77:
Automating Range Surveillance Throu
Page 78 and 79:
Next-Generation Telemetry Workstati
Page 80 and 81:
GPS Metric Tracking UnitAs Global P
Page 82 and 83:
Space-Based RangeSpace-Based Range
Page 85 and 86:
Fluid System TechnologiesKSC Techno
Page 87 and 88:
0.900.850.80Discharge Coefficient,
Page 89 and 90:
Composite seals for performance eva
Page 91 and 92:
140000120000100000Signal80000600004
Page 93 and 94:
Contacts: Dr. Barry J. Meneghelli ,
Page 95 and 96:
60555045Comparative k-value (mW/m-K
Page 97 and 98:
a compatible spacecraft model where
Page 99 and 100:
In an ongoing effort for improvemen
Page 101:
Low-gravity probe prototype test.th
Page 104 and 105:
Countermeasure for Radiation Protec
Page 106 and 107:
Focused Metabolite Profiling for Di
Page 109 and 110:
Process and Human FactorsEngineerin
Page 111 and 112:
DON uses game technology to enable
Page 113 and 114:
Type of mobile crane that impacted
Page 115 and 116:
SALT proof-of-concept communication
Page 117 and 118:
SSLM CAD model.Our design offers th
Page 119 and 120:
Variables that can be integrated by
Page 121:
Exploration Supply Chain Simulation
Page 124 and 125:
Nanosensors for Evaluating Hazardou
Page 126 and 127:
Sixty-four-Channel Inline Cable Tes
Page 128 and 129:
Wireless Inclinometer Calibration S
Page 130 and 131:
Generating Safety-Critical PLC Code
Page 132 and 133:
Spacecraft Electrostatic Radiation
Page 134 and 135:
Ion Beam Propulsion StudySpacecraft
Page 136 and 137:
RT-MATRIX: Measuring Total Organic
Page 139 and 140:
Appendix AKSC High-Priority Technol
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Risk Assessment ToolMission Data Fe
Page 143 and 144:
Appendix BInnovative Partnership Pr
Page 145 and 146:
system for the Government, using th
Page 147:
tracking objects after launch, and
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2006-2007 - Kennedy Space Center Technology Transfer Office

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