Physical Optics Corporation — Department of Defense SBIR Phase I: N161-061

Description

To address the Navys need for a non-aqueous environmentally benign surface preparation for aluminum pre-treatment process, Physical Optics Corporation (POC) proposes to develop a new Active-Feedback Laser Surface Preparation (AFLAP) system. This proposed surface processing method is based on pulsed laser ablation and a novel use of real-time surface quality monitoring with plasma emission spectroscopy. Specifically, the innovation in making treated surface quality information available during preparation will enable this method for preparing aluminum alloy surfaces with homogenous topography and a high level of purity. As a result, this method will produce a highly wettable surface to enable strong hydrothermally stable anodization, surface modification, or conversion coating of aluminum alloy for low-cost repair and rework of aircraft components, with zero chemical use, which directly addresses Navy requirements. In Phase I, POC will demonstrate the feasibility of the proposed method by building a benchtop prototype using commercial off-the-shelf components and conducting proof-of-concept experiments on a laser-processed, anodized aluminum test specimen in accordance with ASTM standards. In Phase II, an operational prototype with a fully developed ablation head will be built and tested. The proposed system is expected to reach technology readiness level (TRL) 5+ at the end of Phase II.