GreenGELAIR aimed at developing a two component sol-gel product to be applied on spray or stick/brush device to improve paint adhesion on large surface for OEM or MRO situations.

It was done through:

• Development of a new and competitive formulation of sol gel product based on hybrid organic-inorganic system. It will be competitive compared to commercial products regarding induction time, pot life and adhesion on surfaces.
• Design of a versatile device capable of providing a wide and accurate range of sol gel on spray or stick/brush.

The Technological objectives are expected to surpass the performances existing in the market:

• Sol gel product.
• Reduce induction time below 30 minutes by means of promoters (acid, UV radiation, organometallics). Sonication will be integrated if necessary.
• Increase the pot life beyond 12 h through optimal formulation with organopolysiloxane precursors.
• Application device.
• Accurate way to dose different components based on a gravimetric system instead of a volumetric one.
• Design a versatile mixing system based on in-line mixing and recirculation. The system will produce the desired quantity and will be adaptable to spray or stick/brush application.
• Design of an integrated cleaning system.
• Evaluation of film.
• Define a new testing methodology to evaluate film performances based on electrochemical controls (Electrochemical noise measurements (ENM), Electrochemical impedance spectroscopy (EIS) and Potentiodynamic Polarization Curves (PPC)).

The new sol gel product and the device designed was compared to conventional processes in complex shapes through a demonstration phase. OEM and MRO situations were considered, Brush and Stick applications were used in MROs scenarios and paint sprayer application was used in OEMs situations. Corrosion and adhesion tests were realised to obtain the comparative study of resulting films. Also, morphology and film thickness was controlled to ensure the adhesion of the film.