Appliqué Coatings Demonstration and Validation

WP-199911

Objectives of the Demonstration

Current coating systems used on Department of Defense (DoD) aircraft provide protection from atmospheric degradation as well as other functions. These systems are generally stripped and repainted every four to six years, a difficult and expensive process with considerable environmental impact. Manufacturers of protective film technologies have recently developed appliqué films aimed at replacing aircraft exterior paints. The objective of this project was to address and quantify issues of application, removal, repair, maintenance, inspectability, and long-term reliability and to asses the cost of using this alternative system.

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Demonstration Results

The demonstration successfully mapped a C-130 aircraft using laser and generated an electronic three-dimensional data file. From this data file, a computer code was developed for an ultrasonic cutter that was used by the Air Force Advanced Composites Office at Hill Air Force Base in Utah to cut appliqué gores for the C-130 aircraft. The project prepared a draft Design Guide and developed the materials for a training workshop. 3M manufactured 15,000 square feet of FP-500 appliqué that passed the initial quality assurance tests and met the appearance and performance requirements. The appliqué technology was demonstrated to the C-130 Program Office and was concluded to be not sufficiently mature to support further testing. 

This project was terminated until the technology becomes sufficiently mature to merit a demonstration and validation effort. (Project Completed - 2000)

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Implementation Issues

Once successfully developed, the appliqué films should provide a durable weather-resistant finish for aircraft. The materials would be available as pre-cut gores or a roll sheet with a protective layer over the adhesive. Application would require simple measuring and cutting tools, and with minimal training, installation should be possible in any enclosed area.

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Points of Contact

Principal Investigator

Mr. Mike Spicer

Air Force Research Laboratory

Phone: 937-255-0942

Fax: 937-255-0954

Program Manager

Weapons Systems and Platforms

SERDP and ESTCP

Document Types

  • Fact Sheet - Brief project summary with links to related documents and points of contact.
  • Final Report - Comprehensive report for every completed SERDP and ESTCP project that contains all technical results.
  • Cost & Performance Report - Overview of ESTCP demonstration activities, results, and conclusions, standardized to facilitate implementation decisions.
  • Technical Report - Additional interim reports, laboratory reports, demonstration reports, and technology survey reports.
  • Guidance - Instructional information on technical topics such as protocols and user’s guides.
  • Workshop Report - Summary of workshop discussion and findings.
  • Multimedia - On demand videos, animations, and webcasts highlighting featured initiatives or technologies.
  • Model/Software - Computer programs and applications available for download.
  • Database - Digitally organized collection of data available to search and access.