USA As Represented by Secretary of the Navy

William M Cicchelli

James R Quartarone

George V Morris

Kenneth E Barthelemy

A process is provided for coating a given surface of a heat sensitive metal article (e.g., thermally massive aluminum) with a high-cure-temperatureating-forming-powder. A first oven heating step elevates the metal article's temperature to a predetermined preheat cycle high-limit-of-heat-load-temperature. After a first predetermined period of time, the metal alloy article is withdrawn from the oven. A high-cure-temperature-coating-forming-powder is then sprayed onto the given surface of the metal article. The spraying, comprising first and second spray sequences, is initiated essentially immediately after withdrawal of the metal article from the oven. The first spray sequence is a single group of spray passes that applies a coating layer to fill the pores in the given surface with heat melted high-cure-temperature-coating-forming-powder. The second spray sequence builds up the total thickness of coating. A second oven heating step elevates the metal article's temperature to a predetermined cure cycle high-limit-of-heat-load-temperature for a second predetermined period of time.

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Saunderstown, RI, United States of America

William M Cicchelli