The APW100 Airframe Protection Series
Taking the Aviation Industry into the 21st Century With New Corrosion Prevention Technology

Superior Protection

More durable compared to traditional corrosion inhibiting compounds (CIC)

Water-Based Technology

Zero volatile organic compounds for safe working conditions

Cost & Time Savings

Reduce application and curing time for greater productivity and workflow

Environmentally Friendly

Less weight compared to CIC, less fuel consumption, less carbon emission

One of the biggest challenges in aviation is to prevent corrosion in metallic airframe structures and components and keep aircraft flying safely.  In general, the goal is to minimize corrosion damage to a “Level 1” classification from one maintenance cycle to the next.  This is traditionally done by layering protective measures, sometimes including physical barriers, to prevent moisture from penetrating to the metal substrate and initiating the corrosion process.  However, despite the industry’s best efforts, corrosion damage exceeding Level 1 is still a harsh reality.  Multiple protective measures can still fail sequentially over time, allowing moisture to reach the metallic substrate and cause corrosion damage.

AeroPel is a nanocomposite protective layer (NPL) is formulated to provide superior protection for airframe structures and components.  AeroPel NPL is the next generation in corrosion prevention, with other benefits and applications yet to be imagined.

How can AeroPel better protect against corrosion?

Based on breakthrough nanotechnology, AeroPel NPL creates a low surface energy for the substrate to repel moisture from the protected area.  The low surface energy forces moisture to bead up instead of “wetting” the protected substrate.  By not allowing the moisture to wet and remain in full contact with the protected substrate, it prevents the moisture from breaking down the protective measures over time to initiate the corrosion process in the metal underneath.

With a superior bond strength to the substrate, resistant to chemicals and abrasion, AeroPel NPL provides a robust protection for both bare metal and existing organic-based protective measures. AeroPel NPL is inherently durable and outperforms traditional organic-based corrosion inhibiting compounds.

Low Surface Energy Concept - The water droplet on the left is placed on a bare aluminum surface compared to the water droplet on the right is placed on a surface protected by the NPL. Note the NPL is forcing the droplet to bead up instead of wetting the surface.

The APW100 Airframe Protection Series is an environmentally-friendly, water-based NPL, a first in the aviation industry for corrosion prevention measures. The NPL is extremely robust and can also serve to protect against erosion, especially when used externally on an aircraft.  Due to its durability, only a thin film (~0.001” or 0.025mm) is required to provide the corrosion/erosion protection.  With a lower dry weight of the thin film compared to traditional corrosion inhibiting compounds, weight saving is achievable to reduce fuel consumption and, ultimately, carbon emissions over the operational life of the aircraft.

AeroPel NPL cures under one hour to the touch to reduce workflow interruption.  In addition, with zero VOC, workflow in confined space can progress during the application process to maintain productivity.

Key Benefits

  • Strong adhesion – Minimize bond-line failure that would allow moisture to penetrate to the substrate and initiate the corrosion process
  • Low viscosity to penetrate and seal structural joints for better corrosion protection
  • Thin film resulting in reduced dry weight
  • Fast curing time – Less idle time within the workflow
  • Functional under extreme temperatures from -60°F to 400°F (-51°C to 204°C)
  • Non-VOC and non-biocidal – Minimal personal protective equipment required for personnel
  • Non-hazardous – No restrictions for transportation and storage
  • Solvent removable
  • Baseline NPL is transparent; tinting is optional for visual identification purposes
Example of failing traditional Corrosion Inhibiting Compound (CIC)
Fuselage skin & frame corrosion damage: Moisture penetrated CIC, primer, and chemical conversion.
Fuselage skin corrosion damage: exhaust vent moisture penetrated organic-based topcoat, primer, and chemical conversion.
Fuselage cargo door cutout structure: moisture penetrated CIC, primer, and chemical conversion.

Proven Technology

The Airframe Protection Series is developed from a baseline nanotechnology application with proven success in the energy and marine industries.  The fundamental science has effectively helped these industries to prevent corrosion and erosion damage to a vast network of infrastructure and investment worldwide.  AeroPel NPL aims to bring the same success to the aviation industry.  The APW100 Series offers solutions to meet specific needs and challenges to protect airframe structures and components against corrosion and beyond.