N131-034 TITLE: Improved Anti-Corrosion Coatings for Undersea Cable Connectors

TECHNOLOGY AREAS: Materials/Processes

ACQUISITION PROGRAM: PMS450, VIRGINIA Class Submarine Program Office

OBJECTIVE: Advance the state of the art in anti-corrosion coatings to develop a robust nonconductive coating suitable for bonding to various connectors in the outboard environment.

DESCRIPTION: Outboard cabling connectors in Navy Submarines are continually exposed to a harsh saltwater environment. Nonconductive coatings, such as those described in [7], are used to extend the service life of outboard connectors. This SBIR will investigate, develop, and demonstrate a new generation of corrosion resistant coatings for outboard connector applications. It is anticipated that advanced anti-corrosion coatings could have a major impact in extending the service life of outboard connectors and cables. Currently, the application of anti-corrosion coatings is limited to flat or cylindrical surface geometries due to the need for uniform coating thickness [6]. There are a large number of outboard connector types in Navy Submarines that are unable to be coated using current technology. A coating material and/or process that is applicable to more complex surface geometries is highly desirable. Connectors may also have vulcanized rubber over-molds, which coatings are currently not applied to. Relevant advances in coating technology [1,2,3,4,5] indicate it may be possible to develop a coating material and/or process suitable for more complex surface geometries and rubber over-molds. The technology developed by this SBIR will be capable of coating, with uniform thickness, surfaces with 90 degree angles. Surface materials may consist of Monel, 316 stainless steel, titanium, and vulcanized rubber. Technologies of interest include, but are not limited to, deionizing plasma coatings and nonfriction plasma coatings.

PHASE I: The company will develop concepts for advanced anti-corrosion coatings that meet the requirements described above. The company will demonstrate the feasibility of the concepts in meeting Navy needs and will establish that the concepts can be feasibly developed into a useful product for the Navy. Feasibility will be established by material testing and analytical modeling. By the conclusion of Phase 1, identify which concepts will be pursued in subsequent phases. The company will provide a Phase II development plan with performance goals and key technical milestones, and will address technical risk reduction.

PHASE II: Based on the results of Phase 1 and the Phase II development plan, the company will develop a prototype for evaluation as appropriate. The prototype will be evaluated to determine its capability in meeting the performance goals as defined in Phase II development plan. Coating performance will be demonstrated through prototype evaluation and modeling or analytical methods over the required range of parameters including numerous deployment cycles in the outboard submarine environment. Evaluation results will be used to refine the prototype into an initial design that will meet Navy requirements. The company will prepare a Phase III development plan to transition the technology to Navy use.

PHASE III: If Phase II is successful, the company will be expected to support the Navy in transitioning the technology for Navy use. The company will develop a prototype suitable for installation aboard a US Navy Submarine. Develop materials, drawing packages, manuals, and documentation to aid in installation and testing of prototypes shipboard during extended operational periods. Conduct all required conformance testing. Support the Navy for test and validation to certify and qualify the system for Navy use.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: The potential applications for an anti-corrosion coating that is compatible with complex surface geometries are numerous. The technology developed in this SBIR could potentially be used anywhere corrosion control is required. This could include maritime structures, commercial shipbuilding, and civil / environmental engineering applications (such as [2]).

REFERENCES:
1. Poon, R.W. "Improved Corrosion Resistance of Plasma Carbon Coated NiTi Orthopedic Materials." Plasma Science, 31st IEEE International Conference on. July 2004.

2. Liu, H. "Research on Preparation and Properties of Multi-Function Anti-Corrosion Coating used to Inner Wall of Water Pond in Service Area of Express Highway." Remote Sensing, IEEE International Conference on. June 2011.

3. Nie, X. "Abrasive Wear / Corrosion Properties and TEM Analysis of Al203 Coatings Fabricated using Plasma Electrolysis." Surface and Coatings Technology 149. January 2002.

4. D. Greenfield and F. Clegg, "Enhancement of Barrier Properties in Organic Coatings Using Nanocomposites", Journal of Corrosion Science and Engineering, 8, 8 (2004)

5. W.J. van Ooij et al., "Silane-based Chromate Replacements for Corrosion Control, Paint Adhesion, and Rubber Bonding", Surface Engineering, 16, 386 (2000).

6. A.L. Bray and C.P. Thornton, "Phase II SBIR Final Technical Report: Non-Conductive Coatings For Underwater Connector Backshells", SBIR Phase II Report, Contract Number N00024-93-C-4124, (1995).

7. Naval Sea Systems Command. "S9320-AM-PRO-030/MLDG: Plasma Spray Procedure." Technical Manual, Underwater Cable and Encapsulated Components Fabrication, Repair, and Installation Manual. Volume II.

KEYWORDS: Corrosion; Nonconductive Coatings; Plasma Coatings; Deionizing Coatings; Vulcanized Surfaces; Submarine Outboard Cables

** TOPIC AUTHOR (TPOC) **

DoD Notice:   Between 16 November, 2012 through 16 December 2012, you may talk directly with the Topic Authors (TPOC) to ask technical questions about the topics. Their contact information is listed above. For reasons of competitive fairness, direct communication between proposers and topic authors is not allowed starting 17 December, 2012, when DoD begins accepting proposals for this solicitation.

However, proposers may still submit written questions about solicitation topics through the DoD's SBIR/STTR Interactive Topic Information System (SITIS), in which the questioner and respondent remain anonymous and all questions and answers are posted electronically for general viewing until the solicitation closes. All proposers are advised to monitor SITIS (13.1 Q&A) during the solicitation period for questions and answers, and other significant information, relevant to the SBIR 13.1 topic under which they are proposing.

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