Method for coating faying surfaces of aluminum-alloy components and faying surfaces coated thereby

Abstract

An aluminum-alloy, aircraft structural component having a faying surface prepared by treating with one or more curable organic coatings, one or more of which is optionally in an encapsulated state, and delivering a uniform coating on demand by rupturing and curing the encapsulated coating.

What is claimed is:  
     
         1 . A method for preparing an aluminum-alloy, aircraft component comprising the steps of: 
 providing an aluminum-alloy component precursor curable to a final state;    providing a curable organic coating material having a non-volatile portion that is predominantly organic and is curable at about a heat-treatment temperature of the aluminum-alloy component;    coating the component precursor with the organic coating material; and    treating the coated aluminum-alloy component precursor to both treat the aluminum to the final state and cure the organic coating.    
     
     
         2 . The method of  claim 1 , wherein the curable organic coating material is encapsulated.  
     
     
         3 . The method of  claim 1 , wherein the step of treating the coated, aluminum-alloy component comprises heat-treating.  
     
     
         4 . The method of  claim 3  wherein the step of treating the coated aluminum-alloy component comprises precipitation heat-treating.  
     
     
         5 . The method of  claim 1 , wherein the step of treating the coated aluminum-alloy component includes pressure-treating.  
     
     
         6 . The method according to  claim 1 , further comprising the steps of 
 positioning the coated aluminum-alloy component in an assembly position contacting a second component; and    providing a compressive force to at least one component.    
     
     
         7 . The method of  claim 1 , wherein the step of providing an aluminum-alloy precursor includes providing an aircraft component selected from the group consisting of wing and fuselage skin panels, stiffeners, frames, and hinges.  
     
     
         8 . The method of  claim 1 , wherein the step of providing an aluminum-alloy precursor includes the step of providing a wing skin panel and components thereof.  
     
     
         9 . The method of  claim 1 , wherein the step of providing an aluminum-alloy component precursor includes the step of providing an aluminum-alloy component precursor in its fully solution-treated and annealed state.  
     
     
         10 . The method of  claim 1 , further comprising the step of providing and applying a second coating to the once coated component.  
     
     
         11 . The method of  claim 1 , further comprising the step of first anodizing the component provided.  
     
     
         12 . The method of  claim 10 , wherein the second coating is an encapsulated coating.  
     
     
         13 . The method of  claim 1 , wherein the component precursor is naturally-aged.  
     
     
         14 . The method of  claim 1 , wherein the component precursor is artificially-aged.  
     
     
         15 . The method of  claim 1 , wherein the organic coating is cured and the component precursor is treated to the final state substantially simultaneously.  
     
     
         16 . The method of  claim 1 , wherein the component precursor has a faying surface.  
     
     
         17 . The method of  claim 1 , wherein the curable organic coating material comprises a phenolic resin.  
     
     
         18 . The method of  claim 1 , wherein the encapsulated curable organic coating material is selected from the group consisting of phenolics, urethanes, epoxies, and melamines.  
     
     
         19 . The method of  claim 1 , wherein the curable organic coating material is selected from the group consisting of polyurethanes, polyvinyl chlorides, silicones, epoxides, acrylates, polyimides and phenolics.  
     
     
         20 . The method of  claim 1 , wherein the step of treating the component precursor includes providing a heat-treatment sufficient to rupture the encapsulated coating to disperse a uniform coating to the aluminum-alloy component precursor surface.  
     
     
         21 . The method of  claim 1 , further comprising the step of providing a substantially uniform first coating deposited to a thickness of from about 0.005 to about 0.010 inch.  
     
     
         22 . The method of  claim 10 , wherein the second coating is selected from the group consisting of phenolics, epoxies, melamines, and polyurethanes/polyureas.  
     
     
         23 . The method of  claim 22 , wherein the second coating is deposited to a thickness of from about 0.0005 to about 0.0015 inch.  
     
     
         24 . The method of  claim 1 , further comprising the steps of 
 providing a second encapsulated coating material;    coating the heat-treated, aluminum-alloy component with a second, encapsulated coating material; and    rupturing the second, encapsulated coating material to disburse a uniform coating.    
     
     
         25 . The method of  claim 24 , wherein the step of providing a second, encapsulated coating material further comprises providing a catalyst.  
     
     
         26 . The method of  claim 24 , wherein the step of providing a second coating includes the step of providing a catalyst selected from the group consisting of Friedel-Crafts acids, Friedel Crafts bases, peroxides, and azo-bis-nitriles.  
     
     
         27 . The method of  claim 24 , wherein the step of providing a second, encapsulated coating material includes providing an adhesive as a substantially uniform layer having a thickness of from about 0.0005 inch to about 0.0015 inch.  
     
     
         28 . The method of  claim 27 , wherein the step of providing a second coating further comprises providing an adhesive selected from the group consisting of phenolics, urethanes, epoxies, and melamines.  
     
     
         29 . The method of  claim 24 , wherein the step of rupturing the second coating material includes the step of liberating the second coating material by heat-treating.  
     
     
         30 . The method of  claim 24 , further comprising the step of liberating the second coating material by exposing the second, encapsulated coating material to an increased pressure of from about 1500 to about 2500 psi.  
     
     
         31 . The method of  claim 24 , further comprising the step of liberating the second coating material by applying pressure to the surface of the coated component.  
     
     
         32 . The method of  claim 24 , wherein the component precursor has a faying surface.  
     
     
         33 . An aluminum-alloy aircraft component prepared according to the method of  claim 16 .  
     
     
         34 . A treated, aluminum-alloy aircraft component prepared according to the method of  claim 32 .  
     
     
         35 . A method for treating an aluminum-alloy, aircraft component having a faying surface comprising the steps of: 
 providing an aluminum-alloy component;    providing a first coating material;    applying the first coating material to the component;    providing a second coating material to the coated component;    applying the second coating material to the component; and    heat-treating the twice-coated component.    
     
     
         36 . The method of  claim 35 , wherein the second coating material is an encapsulated coating.  
     
     
         37 . The method of  claim 35 , further comprising the step of anodizing the component before the first coating is applied.  
     
     
         38 . The method of  claim 35 , wherein the step of providing a first coating material includes the step of providing coating materials selected from the group consisting of phenolics, epoxies, urethanes, silicones, novolaks, acrylates, and melamines.  
     
     
         39 . The method of  claim 35 , wherein the step of providing an encapsulated coating includes the step of providing a second coating material selected from the group consisting of phenolics, epoxies, urethanes, novolaks, melamines, acrylates, and silicones.  
     
     
         40 . The method of  claim 35 , wherein the step of heat-treating the component includes the step of heating the component to a temperature of from about 120 to about 180 degrees F. for a time of from about 20 minutes to about 1 hour.  
     
     
         41 . The method of  claim 35 , further comprising the step of providing pressure to the component other than ambient pressure.  
     
     
         42 . The method of  claim 35 , wherein the component is naturally-aged.  
     
     
         43 . The method of  claim 35 , wherein the component is artificially-aged.  
     
     
         44 . The method of  claim 35 , wherein the component has a faying surface.  
     
     
         45 . A treated, aluminum-alloy aircraft component having a faying surface prepared according to the method of  claim 35 .  
     
     
         46 . An aluminum-alloy aircraft component prepared according to the method of  claim 35 .  
     
     
         47 . A method for treating an aluminum-alloy, aircraft component having a faying surface comprising the steps of: 
 providing an aluminum-alloy, aircraft component;    providing a first coating;    providing a second coating;    applying the first and second coating to the component in sequential order;    providing a releasable film; and    applying the releasable film to the component to cover the second coating.    
     
     
         48 . The method of  claim 47 , wherein the second coating comprises encapsulators.  
     
     
         49 . An aluminum-alloy, aircraft component having a faying surface prepared according to the method of  claim 47 .  
     
     
         50 . A method for treating an aluminum-alloy, aircraft component having a faying surface comprising the steps of: 
 providing an aluminum-alloy, aircraft component;    providing a first coating;    applying the first coating to the component;    heat-treating the component;    providing an encapsulated second coating;    applying the second coating to the coated component;    providing a releasable film; and    applying the releasable film to the component to cover the second coating.    
     
     
         51 . The method of  claim 50 , wherein the second coating comprises encapsulators.  
     
     
         52 . An aluminum alloy-aircraft, component having a faying surface prepared according to the method of  claim 50 .  
     
     
         53 . A method for treating an aluminum-alloy aircraft, component having a faying surface comprising the steps of: 
 providing an aluminum-alloy aircraft component;    providing a first coating;    applying the first coating to the component to make a once-coated component;    providing a first heat-treatment to the component;    providing a second coating in an encapsulated state;    applying the second coating to the coated component to make a twice-coated component; and    positioning the component for assembly.    
     
     
         54 . The method of  claim 53 , further comprising the step of positioning the twice-coated component into a final assembly position.  
     
     
         55 . The method of  claim 53 , further comprising the step of providing a force to the twice-coated component sufficient to liberate the encapsulations of the second coating.  
     
     
         56 . The method of  claim 53 , wherein the step of providing a force to the component includes providing a pressure in the range of from about 1500 psi to about 2500 psi.  
     
     
         57 . The method of  claim 53 , wherein the step of providing a force to the component is a compressive force in the range of from about 1500 psi to about 2500 psi.  
     
     
         58 . An aluminum-alloy aircraft component prepared according to the method of  claim 53 .  
     
     
         59 . An aircraft component having faying surfaces and made from an aluminum alloy comprising: 
 a uniformly deposited, first corrosion-resistant, available organic coating material having a thickness of from about 0.0050 inch to about 0.010 inch; and    an encapsulated second coating comprising a polyurethane/polyuria and uniformly deposited to a thickness of from about 0.0005 inch to about 0.0015 inch;    wherein the surface of the first coating is tack free.    
     
     
         60 . An aircraft having faying surfaces, said aircraft made from aluminum-alloy containing components, said components comprising: 
 a first coating; and    a second coating;    wherein said coatings and said component are substantially simultaneously cured in one curing step.