Looking for a High-performance Anti-corrosion Coating for Aluminum, Composites and Painted Parts

Type of Solution sought

A material (coating ingredient or formulated coating)
A technology
A partner to develop or co-develop the coating

Description of Desired Solution

A SpecialChem client, a global company tier 1 in the industry of transportation is seeking a new solution protecting aluminum alloys, composites (Carbon Fiber Reinforced Polymer) and epoxy painted parts against corrosion for 3000h in salt spray test (ASTM B117), with a water resistance for more than 2000h in controlled condensation atmosphere (ASTM D 4585).

Background

New materials/substrates are continuously developed in order to match the expanding demand for robust and reliable transportation systems. In this context, the transportation field is continuously looking for solutions to protect their structures against corrosion. The coating will be used on existing structures already designed and commercialized. This project is directly coming from an identified need at OEMs. The current solution is monopolistic, so alternatives are strongly expected by OEMs.

The expected market value for this coating is 2M€/year.

Detailed Solution Description

The innovative coating must meet the following critical requirements:

Salt Spray test (ASTM B117): 3000 hours on aluminum alloy
Condensation test (ASTM D 4585): 2000 hours @ 40°C
Resistant to thermal cycling (adhesion, flexibility...)
Adhesion to aluminum, composites (Carbon Fiber Reinforced Polymers) and epoxy painted substrates

Other key characteristics of importance for the coating are:

Solvent based chemistry with a Flash Point > 40°C
Shelf-life: at least 1 year
One component, ready to use coating
Air drying system
Applied in one layer around 20-50µm thick (dry)
Dry to touch in less than 4 hours @ 23°C/60% HR
Viscosity
High chemical resistance to alcohols, acids and bases
Removable with organic solvents
REACH compliant

Possible Routes To Investigate

Among previous solutions evaluated which did not fully satisfy the requirements (but which could still be considered if they meet the requirements listed in the "Detailed Solution Description" section):

Alkyd resins
Hydrocarbon resins
Urethane-based resins
Maleic resins

In a general manner, the solution should include REACH-registered raw materials and industrially oriented solutions, up to few thousand liters per batch.

Solution that are not of interest

The solution that are prohibited:

Water-based systems
Silicone-based chemistry
CMR classified solvents
Chromate-based [Cr(VI)] inhibitors
A two-components solution is also forbidden

Anticipated Next Steps with Respondents

Looking for quickly available solutions - Manufacturing and Market implementation within 1-2 years.

Other Comments / Important Considerations

The final coating will be manufactured and commercialized by SpecialChem client.

Type of Outcome expected

The SpecialChem Client is open to a wide spectrum of proposals’ maturity.

- For coatings formulations: a proof of concept of Technology Readiness Level (TRL) 4 on the NASA TRL scale (Validation in laboratory environment. This includes basic technological components are integrated to establish that they will work together. Examples include integration of “ad hoc” hardware in the laboratory )

And

- For raw materials: an Actual System Proven through Successful Usage of TRL 9 (Actual application of the technology in its final form and conditions. Technology is commercially available)

In case you would like to submit a proposal, please indicate the TRL of your solution:

TRL#	Technology Readiness Level	Description
1	Basic principles	Lowest level of technology readiness. Scientific research begins to be translated into applied research and development (R&D). Examples might include paper studies of a technology’s basic properties.
2	Technology concept	Basic principles are observed. Applications are speculative, and there may be no proof or detailed analysis to support the assumptions. Examples are limited to analytic studies.
3	Proof of concept	Active R&D is initiated. This includes analytical studies and laboratory studies to physically validate the analytical predictions of separate elements of the technology. Examples include components that are not yet integrated or representative.
4	Validation in laboratory environment	Basic technological components are integrated to establish that they will work together. Examples include integration of “ad hoc” hardware in the laboratory.
5	Validation in relevant environment	The basic technological components are integrated with reasonably realistic supporting elements so they can be tested in a simulated environment. Examples include laboratory integration of components.
6	Prototype demonstration in a relevant environment	Representative model or prototype system, which is well beyond that of TRL 5, is tested in a relevant environment. Represents a major step up in a technology’s demonstrated readiness. Examples include testing a prototype in a laboratory environment or in a simulated operational environment.
7	System prototype demonstration in an operational environment	Prototype near or at planned operational system. Represents a major step up from TRL 6 by requiring demonstration of an actual system prototype in an operational environment.
8	Actual system completed and qualified through test and demonstration	Technology has been proven to work in its final form and under expected conditions. In almost all cases, this TRL represents the end of true system development. Examples include developmental test and evaluation (DT&E) of the system in its intended system to determine if it meets design specifications.
9	Actual system proven through successful usage	Actual application of the technology in its final form and conditions. Technology is commercially available.

Company Demographics

Industry our client is in: Transportation
Annual Revenue: >50 million EUR
Years in Business: >40 Years
Headquarters Area: Europe

Business considered

Licensing
Contractual partnership
Buying
R&D development / co-development