[Objective]To investigate the effect of highly conductive coatings on the corrosionresistance of aluminum alloy aircraft skins.[Methods]Three types of aircraft skin surface conditions(bare aluminum alloy,anodic oxidation sealed by chromate(AAO)and anodic oxidation painted with primer)were designed based on the actual conditions of aluminum alloy skins during production andrepair. The galvanic corrosion effects of conductive coatings on anodized-sealed and primer-coatedaluminum alloy skins were studied via polarization curves and galvanic corrosion tests. A neutral saltspray test was used to evaluate the corrosion resistance of coating systems.[Results]The conductive coating contains 78. 8% flake silver powder as the conductive filler,achieving high conductivity of thecoating. The potential differences between the highly conductive coating and both bare aluminum alloyand sealed anodized aluminum alloy exceed 0. 25 V,which result in uniform corrosion on bare aluminum alloy and pitting corrosion on sealed anodized aluminum alloy. The micropores in the highlyconductive coating could establish a pathway for the diffusion of corrosive media between the conductive powder and substrates,which could cause galvanic corrosion of the bare aluminum alloy and AAO substrate during the salt spray test. The application of an anticorrosive primer effectively mitigatedthe galvanic corrosion effect of the conductive coating on aluminum alloy.[Conclusion]The highlyconductive coating can reduce the corrosion resistance of bare aluminum alloy and AAO to neutral saltspray. The use of epoxy-modified polyurethane primer(thickness should be controlled above 20 μm) can isolate the aluminum alloy substrate from galvanic corrosion induced by the highly conductivecoating and enhance the corrosion resistance of aluminum alloy skin.
LIU Zeyu
,
DUN Yuchao
,
LI Wen
,
CHENG Ming
,
LI Shaojie
,
ZHANG Xiaochen
,
WEI Guoke
,
CHEN Yazheng
,
DONG Chunlei
. Effect of Silver-based Highly Conductive Epoxy Coatings on Corrosion Resistance of Aluminum Alloy Skin[J]. Paint & Coatings Industry, 2026
, 56(4)
: 22
-28
.
DOI: 10.12020/j.issn.0253-4312.2025-146