Research Progress on Chemical Conversion Coatings for Aeronautical Aluminum Alloys Based on MIL-DTL-5541

LIU Kangle; CHEN Xiuxian; HUA Haokai

doi:10.7643/issn.1672-9242.2026.04.012

PDF(13260 KB)

Equipment Environmental Engineering ›› 2026, Vol. 23 ›› Issue (4) : 123-133. DOI: 10.7643/issn.1672-9242.2026.04.012

Aviation and Aerospace Equipment

Research Progress on Chemical Conversion Coatings for Aeronautical Aluminum Alloys Based on MIL-DTL-5541

LIU Kangle^*, CHEN Xiuxian, HUA Haokai

Author information +

History +

Abstract

Based on the hexavalent chromium and non-hexavalent chromium system defined by the MIL-DTL-5541 standard, this paper systematically reviews the research progress of chemical conversion coatings for typical aerospace aluminum alloys. It emphasizes the film-forming mechanisms and microstructural characteristics of chemical conversion coatings and analyzes the impact of such coatings on the environmental suitability of aluminum alloys according to the key performance indicators outlined in relevant standards, particularly corrosion resistance and coating adhesion. On this basis, the current shortcomings in the validation of environmental suitability of chemical conversion coatings for aerospace aluminum alloys are summarized, aiming to offer valuable insights for further research.

Key words

aviation aluminum alloys / chemical conversion coatings / hexavalent chromium / non-hexavalent chromium / corrosion resistance / environmental suitability

Cite this article

EndNote

Ris (Procite)

Bibtex

Download Citations

LIU Kangle, CHEN Xiuxian, HUA Haokai. Research Progress on Chemical Conversion Coatings for Aeronautical Aluminum Alloys Based on MIL-DTL-5541[J]. Equipment Environmental Engineering. 2026, 23(4): 123-133 https://doi.org/10.7643/issn.1672-9242.2026.04.012

References

[1] PAI A, RODRIGUEZ-MILLAN M, SHENOY B S.Aerospace Grade Aluminum Alloys[M]//Aluminum Technologies in Aerospace Applications. Cham: Springer Nature Switzerland, 2025: 1-13.
[2] LI S S, YUE X, LI Q Y, et al.Development and Applications of Aluminum Alloys for Aerospace Industry[J]. Journal of Materials Research and Technology, 2023, 27: 944-983.
[3] 崔腾飞, 刘道新, 徐星辰, 等. 高强度铝合金典型沿海地区腐蚀行为加速试验方法研究[J]. 装备环境工程, 2020, 17(5): 33-39.
CUI T F, LIU D X, XU X C, et al.Accelerated Test Method for High Strength Aluminum Alloy in Typical Coastal Area[J]. Equipment Environmental Engineering, 2020, 17(5): 33-39.
[4] STARTSEV V O, GORBOVETS M A, VALEVIN E O, et al.Comparison of Corrosion Resistance of Aviation Aluminum Alloys in the Coastal Atmosphere of Moderately Warm and Humid Tropical Climates[J]. Steel in Translation, 2024, 54(1): 62-69.
[5] MCFALL-BOEGEMAN S.Investigation of the Anti-Corrosion Properties of Trivalent Chromium Process Coatings on Various Surface Pretreatments of Aerospace Aluminum Alloys[D]. East Lansing: Michigan State University, 2021: 7-10.
[6] YUE J Y, CAO Y.Corrosion Prevention by Applied Coatings on Aluminum Alloys in Corrosive Environments[J]. International Journal of Electrochemical Science, 2015, 10(7): 5222-5237.
[7] 白玉洁, 孟迪, 李新义, 等. 高强铝合金模拟极寒大气环境下加速腐蚀机理研究[J]. 装备环境工程, 2025, 22(8): 1-13.
BAI Y J, MENG D, LI X Y, et al.Study on Accelerated Corrosion Mechanism of High-Strength Aluminum Alloy under Simulated Extremely Cold Atmospheric Environment[J]. Equipment Environmental Engineering, 2025, 22(8): 1-13.
[8] PROENÇA C S, PEREIRA A M, PIGLIARU L, et al. Alternative Chemical Conversion Pre-Treatment for Aeronautical Aluminium Alloy: Characterisation and Anticorrosion Performance[J]. CEAS Space Journal, 2023, 15(1): 265-280.
[9] WHITMAN B W, LI L L, SWAIN G M.Anti-Corrosion Properties of a TCP Pretreatment Conversion Coating on Aluminum Alloy 2024-T3 during Moist SO₂Atmospheric Testing: Effects of Galvanic Coupling[J]. Journal of the Electrochemical Society, 2017, 164(4): C135-C147.
[10] Chemical Conversion Coatings on Aluminum and Aluminum Alloys: MIL-DTL-5541F NOT 2[S]. Department of Defense.
[11] 黄海亮, 卞贵学, 李一哲, 等. 铝合金微电偶腐蚀机理与数值模拟研究进展[J]. 装备环境工程, 2024, 21(5): 74-81.
HUANG H L, BIAN G X, LI Y Z, et al.Advances in Micro-Coupling Corrosion Mechanism and Numerical Simulation of Aluminum Alloy[J]. Equipment Environmental Engineering, 2024, 21(5): 74-81.
[12] YU C Q, FENG Y C, WANG L, et al.Effect of Pre- Stretching Deformation Treatment Process on Microstructure and Mechanical Properties of Al-Cu-Mg Alloy[J]. Materials Today Communications, 2022, 31: 103368.
[13] ALI H, STEIN Z, FOULIARD Q, et al.Computational Model of Mechano-Electrochemical Effect of Aluminum Alloys Corrosion[J]. Journal of Engineering for Gas Turbines and Power, 2022, 144(4): 041004.
[14] AL-HAIDARY J T, HADDAD J S, ALFAQS F A, et al. Susceptibility of Aluminum Alloy 7075 T6 to Stress Corrosion Cracking[J]. SAE International Journal of Materials and Manufacturing, 2021, 14(2): 195-202.
[15] 李明祥, 张政斌, 孙宝龙. 航空铝合金Alodine氧化工艺及质量控制[J]. 工具技术, 2014, 48(8): 85-88.
LI M X, ZHANG Z B, SUN B L.Alodine Oxidation Process and Quality Control for Aviation Aluminum Alloy[J]. Tool Engineering, 2014, 48(8): 85-88.
[16] CAMPESTRINI P, GOEMINNE G, TERRYN H, et al.Chromate Conversion Coating on Aluminum Alloys[J]. Journal of the Electrochemical Society, 2004, 151(2): B59.
[17] EVERTSSON J, BERTRAM F, ZHANG F, et al.The Thickness of Native Oxides on Aluminum Alloys and Single Crystals[J]. Applied Surface Science, 2015, 349: 826-832.
[18] JAKAB M A, LITTLE D A, SCULLY J R.Experimental and Modeling Studies of the Oxygen Reduction Reaction on AA2024-T3[J]. Journal of the Electrochemical Society, 2005, 152(8): B311.
[19] LI L Z.Corrosion Protection Provided by Trivalent Chromium Process Conversion Coatings on Aluminum Alloys[D]. East Lansing: Michigan State University, 2013: 7-13.
[20] PROENÇA C S, PEREIRA A M, CABRAL A M, et al. Trivalent Chromium Conversion Coating on AA2024-T3 Used in Aeronautical and Aerospace Industry[J]. Surface and Interface Analysis, 2019, 51(12): 1298-1311.
[21] 王花蕾. 铝及铝合金Alondine 1200S化学转化膜层工艺的应用研究[J]. 现代工业经济和信息化, 2017, 7(18): 37-38.
WANG H L.Study on the Application of Chemical Conversion Coating Process of Aluminum Alloy Alondine 1200S[J]. Modern Industrial Economy and Informationization, 2017, 7(18): 37-38.
[22] 孙境尧, 郭利雄, 张胜宝. 3型阿洛丁工艺路线及参数探究[J]. 科技展望, 2016, 26(16): 121-121.
SUN J Y, GUO L X, ZHANG S B.Study on Process Route and Parameters of 3-Type Alodine[J]. Science and Technology, 2016, 26(16): 121-121.
[23] 王顺, 王熙娴. 浅谈Alodine1500氧化参数对转化膜层影响及漆层结合力的改善方法[J]. 科技创新导报, 2020, 17(11): 60-61.
WANG S, WANG X X.Discussion on the Influence of Oxidation Parameters of Alodine1500 on Conversion Coating and the Improvement Method of Coating Adhesion[J]. Science and Technology Innovation Herald, 2020, 17(11): 60-61.
[24] 易俊兰, 秦锐, 吴宏亮, 等. 化学转化处理时间对新型2198铝锂合金耐蚀性的影响[J]. 腐蚀与防护, 2020, 41(12): 26-30.
YI J L, QIN R, WU H L, et al.Effect of Chemical Conversion Time on Corrosion Resistance of a New Aluminum-Lithium Alloy 2198[J]. Corrosion & Protection, 2020, 41(12): 26-30.
[25] 易俊兰, 秦锐, 吴宏亮, 等. 化学转化处理时间对新型2198铝锂合金耐蚀性的影响[J]. 腐蚀与防护, 2020, 41(12): 26-30.
YI J L, QIN R, WU H L, et al.Effect of Chemical Conversion Time on Corrosion Resistance of a New Aluminum-Lithium Alloy 2198[J]. Corrosion & Protection, 2020, 41(12): 26-30.
[26] WALTON J, SHRUTHI T K, YANCEY D, et al.Evaluation of a Trivalent Chromium Process (TCP) Conversion Coating on AA2024-T3 that Requires no Surface Pretreatment[J]. Journal of the Electrochemical Society, 2019, 166(15): C589-C599.
[27] QI J, GAO L, LI Y, et al.An Optimized Trivalent Chromium Conversion Coating Process for AA2024-T351 Alloy[J]. Journal of the Electrochemical Society, 2017, 164(7): C390-C395.
[28] IYER A, WILLIS W, FRUEH S, et al.Characterization of NAVAIR Trivalent Chromium Process (TCP) Coatings and Solutions[J]. Plating and Surface Finishing 2010, 97(4): 32-42.
[29] PEHLIVANOĞLU C, ÖTEYAKA M Ö, HOŞGÜN E Z. Influence of Trivalent Chromium Process (TCP) Concentration on the Anti-Corrosion Protection of 2024-T3 Aluminium Alloy[J]. Canadian Metallurgical Quarterly, 2024, 63(4): 1273-1285.
[30] BHATT H, MANAVBASI A, ROSENQUIST D.Trivalent Chromium for Enhanced Corrosion Protection on Aluminum Surfaces[J]. Metal Finishing, 2009, 107(6): 39-47.
[31] VERDALET-GUARDIOLA X, FORI B, BONINO J P, et al.Nucleation and Growth Mechanisms of Trivalent Chromium Conversion Coatings on 2024-T3 Aluminium Alloy[J]. Corrosion Science, 2019, 155: 109-120.
[32] QI J T, HASHIMOTO T, WALTON J R, et al.Trivalent Chromium Conversion Coating Formation on Aluminium[J]. Surface and Coatings Technology, 2015, 280: 317-329.
[33] SHRUTHI T K, SWAIN G M.Communication—Role of Trivalent Chromium on the Anti-Corrosion Properties of a TCP Conversion Coating on Aluminum Alloy 2024-T3[J]. Journal of the Electrochemical Society, 2018, 165(2): C103-C105.
[34] SMITH P, MILLER C.Assessing the Performance of Chromate-Free Pretreatment Options for CARC Systems Comprehensive Research Efforts Aimed at Prevention and Early Detection of Corrosion in U.S. Military Equipment[J]. Metal Finishing, 2007, 105(9): 62-70.
[35] SUIB S L, LA SCALA J, NICKERSON W, et al.Determination of Hexavalent Chromium in NAVAIR Trivalent Chromium Process (TCP) Coatings and Process Solutions[J]. Metal Finishing, 2009, 107(2): 28-34.
[36] QI J, GAO L, LIU Y, et al.Chromate Formed in a Trivalent Chromium Conversion Coating on Aluminum[J]. Journal of the Electrochemical Society, 2017, 164(7): C442-C449.
[37] LI J H, YAO C L, LIU Y B, et al.The Hazardous Hexavalent Chromium Formed on Trivalent Chromium Conversion Coating: The Origin, Influence Factors and Control Measures[J]. Journal of Hazardous Materials, 2012, 221: 56-61.
[38] CARREIRA A F, PEREIRA A M, VAZ E P, et al.Alternative Corrosion Protection Pretreatments for Aluminum Alloys[J]. Journal of Coatings Technology and Research, 2017, 14(4): 879-892.
[39] MOROSE G, PINSKY D, HUMPHREY C, et al.Evaluation of Conversion Coatings without Hexavalent Chromium for Aerospace and Defense Applications[J]. Journal of Aerospace Technology and Management, 2022, 14: e0522.
[40] MUNSON C A, MCFALL-BOEGEMAN S A, SWAIN G M. Cross Comparison of TCP Conversion Coating Performance on Aluminum Alloys during Neutral Salt-Spray and Thin-Layer Mist Accelerated Degradation Testing[J]. Electrochimica Acta, 2018, 282: 171-184.
[41] HOU B, ZHU L Z.The Study on Performances of Environment-Friendly Colorless Chemical Conversion Coatings on Aluminum Alloy[J]. Journal of Physics: Conference Series, 2023, 2539(1): 012049.
[42] 黄旋. 铝合金环保型钝化技术及其与涂层的配套性研究[D]. 北京: 机械科学研究总院, 2012: 21-63.
HUANG X.Environmentally Friendly Passivation Technology for Aluminum and Supporting Research of the Coating[D]. Beijing: China Academy of Machinery Science and Technology, 2012: 21-63.
[43] O’KEEFE M J, GENG S J, JOSHI S. Cerium-Based Conversion Coatings as Alternatives to Hex Chrome Rare-Earth Compounds Provide Resistance Against Corrosion for Aluminum Alloys in Military Applications[J]. Metal Finishing, 2007, 105(5): 25-28.
[44] RIVERA B F, JOHNSON B Y, O’KEEFE M J, et al. Deposition and Characterization of Cerium Oxide Conversion Coatings on Aluminum Alloy 7075-T6[J]. Surface and Coatings Technology, 2004, 176(3): 349-356.
[45] ALBA-GALVÍN J J, GONZÁLEZ-ROVIRA L, BOTANA F J, et al. Application of Commercial Surface Pretreatments on the Formation of Cerium Conversion Coating (CeCC) over High-Strength Aluminum Alloys 2024-T3 and 7075-T6[J]. Metals, 2021, 11(6): 930.
[46] 马雪菲. 2198铝锂合金表面铈基转化膜的制备及腐蚀行为研究[D]. 沈阳: 沈阳航空航天大学, 2022: 19-44.
MA X F.Study on Preparation and Corrosion Behavior of Cerium-Based Converision Film on 2198 Al-Li Alloy[D]. Shenyang: Shenyang Aerospace University, 2022: 19-44.
[47] 柳绍鑫, 王赫男, 马雪菲, 等. 2198铝锂合金稀土铈化学转化膜的制备及耐蚀性研究[J]. 材料保护, 2024, 57(10): 134-143.
LIU S X, WANG H N, MA X F, et al.Study on the Preparation and Corrosion Resistance of Cerium-Based Chemical Conversion Coating on 2198 Al-Li Alloy[J]. Materials Protection, 2024, 57(10): 134-143.
[48] CASTANO C E, O’KEEFE M J, FAHRENHOLTZ W G. Cerium-Based Oxide Coatings[J]. Current Opinion in Solid State and Materials Science, 2015, 19(2): 69-76.
[49] ZHAN W, QIAN X Z, GUI B Y, et al.Preparation and Corrosion Resistance of Titanium-Zirconium-Cerium Based Conversion Coating on 6061 Aluminum Alloy[J]. Materials and Corrosion, 2020, 71(3): 419-429.
[50] ZHANG H H, ZHANG X F, ZHAO X H, et al.Preparation of Ti-Zr-Based Conversion Coating on 5052 Aluminum Alloy, and Its Corrosion Resistance and Antifouling Performance[J]. Coatings, 2018, 8(11): 397.
[51] PEREIRA A M, PIMENTA G, DUNN B D.ESA STM-276, Assessment of Chemical Conversion Coatings for the Protection of Aluminium Alloys: A Comparison of Alodine 1200 with Chromium-free Conversion Coatings[S]. Noordwijk: European Space Agency, 2008.
[52] RICHARD A. LANE, CHRISTOPHER FINK, CHRISTIAN GRETHLEIN P E. Analysis of Alternatives to Hexavalent Chromium: A Program Management Guide to Minimize the Use of CrVI in Military Systems[M]. Rome: Advanced Materials, Manufacturing and Testing Information Analysis Center, 2012: 43-57.
[53] 张博, 赵焕, 董宇, 等. 2024铝合金表面有色钛锆转化膜的制备与性能研究[J]. 材料保护, 2018, 51(7): 1-5.
ZHANG B, ZHAO H, DONG Y, et al.Preparation and Performance of Colored Ti-Zr Conversion Coating on 2024 Aluminum Alloy[J]. Materials Protection, 2018, 51(7): 1-5.
[54] 李庆鹏. 2024铝合金表面高性能无铬转化膜的制备与性能研究[D]. 沈阳: 东北大学, 2018: 46-95.
LI Q P.Preparation and Properties of High Performance Chromium-Free Conversion Film on 2024 Aluminum Alloy Surface[D]. Shenyang: Northeastern University, 2018: 46-95.
[55] LI L L, WHITMAN B W, MUNSON C A, et al.Structure and Corrosion Performance of a Non-Chromium Process (NCP) Zr/Zn Pretreatment Conversion Coating on Aluminum Alloys[J]. Journal of the Electrochemical Society, 2016, 163(13): C718-C728.
[56] LI L L, WHITMAN B W, SWAIN G M.Characterization and Performance of a Zr/Ti Pretreatment Conversion Coating on AA2024-T3[J]. Journal of the Electrochemical Society, 2015, 162(6): C279-C284.
[57] PENG D D, WU J S, YAN X L, et al.The Formation and Corrosion Behavior of a Zirconium-Based Conversion Coating on the Aluminum Alloy AA6061[J]. Journal of Coatings Technology and Research, 2016, 13(5): 837-850.
[58] 易爱华. 铝合金表面钛/锆转化膜的着色及性能优化[D]. 广州: 华南理工大学, 2012: 26-80, 92.
YI A H.The Coloration and Performance Optimization of Ti/Zr Conversion Coating on Aluminum Alloy[D]. Guangzhou: South China University of Technology, 2012: 26-80, 92.
[59] WANG L L, JIA Y X, LUO Y Q, et al.Study on the Process of Chromium-Free Chemical Conversion Coating of 7075 Aluminum Alloy[J]. Protection of Metals and Physical Chemistry of Surfaces, 2025, 61(2): 448-455.
[60] SANTA COLOMA P, IZAGIRRE U, BELAUSTEGI Y, et al.Chromium-Free Conversion Coatings Based on Inorganic Salts (Zr/Ti/Mn/Mo) for Aluminum Alloys Used in Aircraft Applications[J]. Applied Surface Science, 2015, 345: 24-35.