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The U.S. Navy requires a longer lasting nonskid/nonslip coating system for shipboard service to support next generation airframe operating parameters. Thermal spray coating systems were identified as candidate materials to replace conventional epoxy technology. Laboratory testing was performed on a variety of alloys to determine the best performing and most cost-effective manner in which to achieve the requisite coating characteristics. Twin wire arc spray was selected as the method of application based on literature and industry review for the optimum field application technology; wire selection was determined by industry performance review and via a Government information request. The wire systems selected consisted of two coats, the first coat to provide corrosion protection over an SSPC-SP 5 prepared steel substrate with the second coat providing the anti-slip properties; quality assurance of the panel preparation was in accordance with SSPC-PA2 and PA17. Seven different thermal spray wire candidates underwent a battery of performance testing to determine the most promising candidate(s) for shipboard assessment. Testing included fatigue, bend, impact resistance, wear resistance, chemical immersion, cyclic accelerated corrosion exposure, adhesion and electrochemical analysis. The results showed that three aluminum alloy wires met all the desired characteristics for the desired coating system. The selection and application of these alloys is applicable to any industry that requires a long lasting nonskid /nonslip coating (e.g., offshore oil and commercial shipping).
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