Research Projects

The aerospace industry heavily relies on aluminium and titanium alloys for corrosion protection, with chromate-based coatings being a common method. However, due to the toxicity and carcinogenic nature of hexavalent chromium, chromate-free coatings are being developed. Graphene, with its high surface area, impermeable nature, and excellent electrical conductivity, has been explored for its potential as a corrosion-resistant barrier material. However, defect-free graphene over complex metals is nearly impossible. Graphene-based nanocomposite coatings could overcome these limitations. One solution is to add anodic materials like zinc to graphene-polymer coatings. Two thermoset polymers, epoxy and polyurethane, are proposed as matrix materials. Graphene tends to agglomerate, and achieving proper functionalization and homogeneous dispersion in a viscous polymer matrix is a challenge. The proposal aims to use atmospheric pressure plasma jets to surface treat aircraft structure materials and study their reliability in enhancing anticorrosive coating adhesion. The resistance of graphene-reinforced zinc-rich nanocomposite coatings against synthetic fluids, UV light, and atmospheric corrosion will be evaluated under various atmospheric conditions. The suitability of these coatings will be assessed by investigating friction drag, microstructure, roughness, and corrosion behavior after subsonic speeds. The proposal aims to develop chromate-free, non-toxic, and environment-friendly anticorrosive coatings on partially scaled models made up of aerospace grade aluminium alloy (AA7075) and titanium alloy (6AL-4V) to enhance the service life of aircraft parts and components. Super-adhesive graphene-reinforced zinc-rich nanocomposite coatings on atmospheric plasma treated alloy surfaces will also be developed.