1. Coatings with Exceptional Corrosion Resistance& Extreme Interfacial Bond Strength Joe Farmer, Sasha Rubenchik & Lloyd HackelLLNL-PRES-710893This work was performed under the auspices of theU.S. Department of Energy by Lawrence LivermoreNational Laboratory under contract DE-AC52-07NA27344.Lawrence Livermore National Security, LLC

2. (1) (2) (3)(4a) (4b) (5)(1) The high-performance corrosion resistant film material is advanced with a spool assembly, and bathed with water thatserves as a tamper during laser pulse; (2) A special laser pulse with rectangular beamcross-section is imaged onto the advancinghigh-performance film material bathed with a thin layer of water; (3) The laser pulse generates a high temperature plasma andvery large pressure shearing out a section of film accelerating it to hypersonic velocities; (4) Patches of high-performancecorrosion-resistant film are accelerated and bonded to the substrate in a controlled step-by-step process creating coating; (5)The film patch hits the substrate at an oblique angle, where the high impact velocity induces plastic shear flow at the interfacecreating a high-strength explosive bondLawrence Livermore National LaboratoryLLLLNNL-LP-RPERS-ES-710893 2 3. HVLAD has already been used to deposit corrosion-resistantrefractory metal coatings with explosivelyLawrence Livermore National LaboratoryLLLLNNL-LP-RPERS-ES-710893bonded interfaces Some additional R&D is required to enable thedeposition of production-quality coatings, that arecontinuous and free of defects With that additional work, HVLAD should be relativelyeasy to deploy since it is based upon commerciallysuccessful laser peening technology3 4. Lawrence Livermore National LaboratoryDeploymentLLLLNNL-LP-RPERS-ES-710893 4NIFLaser TechnologyLaserPeeningProcessCommercializationExtension to HVLAD ProcessHigh Performance Coatings withExplosively Bonded Interfaces 5. Unfortunately, conventional processes for the deposition of suchprotective coatings often require high temperatures, the handlingof hazardous powders and chemicals that pose inhalation risks forworkers, and lead to unacceptable porosity, poor interfacial bondstrength, and problematic integrity for many applications. The proposed ambient-temperature HVLAD process requires nochemical or powder feed, and is capable of producing high-performancecoatings with no residual porosity and ultra-stronginterfacial bonds for application in a wide range of extremeenvironments this is the ultimate additive manufacturingprocess.Lawrence Livermore National LaboratoryLLLLNNL-LP-RPERS-ES-7108935 6. HVLAD is effective means of producingcoatings such as Ta and Ta-W alloys withtrue metallurgical bonds ODS FM steels has very good hightemperature strength, but lacks corrosionresistance in exotic high-temperaturecoolants such as molten fluoride salts andliquid metals such as Li, Pb-Li and Pb-Bi HVLAD Ta and Ta-W has exceptionalcorrosion resistance in such extremeenvironments Other coating materials may be optimalfor other applicationsLawrence Livermore National LaboratoryODS Steel Tantalum10mm600 C600 CSlight localized grain boundarypenetration at 900C similar tothat observed with ODS at600C900 C900 CHigh RpreflectsnonexistentkineticsGrainboundarypenetrationreflected inlower RpvaluesGreatly acceleratedcorrosion reflected invery low RpLLLLNNL-LP-RPERS-ES-710893 6 7. Lawrence Livermore National LaboratoryLLLLNNL-LP-RPERS-ES-710893 7Metrics EP or EDElectroplating orElectrodepostionCSCold SprayCoating ProcessHVOFHigh Velocity OxyFuel Coating ProcessHVLADHigh Velocity LaserAccelerated DepositionRange of Materials Narrow Narrow Broad BroadStandard Metals Yes Yes Yes YesRefractory Metals No Tantalum Yes YesCeramics No No Yes YesBond Strength Low-Moderate Moderate Moderate Very HighPowder Feed No Yes Yes NoChemical Feed Yes No No NoDebris Generation No Yes Yes NoProcess Temperature Below 100C Below 200C Above 1000C About 25CEnergy Efficiency High Moderate Low ModerateTanks & Reactors Yes No No YesSecondary Containment Yes Yes Yes NoCapital Cost Low Low Intermediate HighProduction Cost Low Moderate High Very Low 8. High-performance protective coatings are capable of saving the U.S.economy billions of dollars every year For example, the cost of corrosion to the Department of Defense isapproximately $22 billion annually, with another $22 billion lost annuallydue to the deterioration of U.S. infrastructure by corrosive attack Protective coatings of various types are essential for ensuring long servicelives for components in high-temperature power plants these coatingshelp prevent the initiation and propagation of various modes of corrosion The total market for metalizing and galvanizing in the U.S. is estimated toLawrence Livermore National LaboratoryLLLLNNL-LP-RPERS-ES-710893be approximately $1.4 billion8 9. Lawrence Livermore National LaboratoryCatherine Elizondoelizondo1@llnl.govLLLLNNL-LP-RPERS-ES-710893 9