DON26BZ05-NV075 — High Performance Electrolytic Coating Touch-Up Repairs for Aluminum
Below is a brief summary. Please check the full solicitation before applying (link in resources section).
Quick Answer
DON26BZ05-NV075 is a Navy Phase I SBIR topic sponsored by NAVAIR. It funds a portable touch-up applicator for electrolytic conversion coating repairs, bridging the performance gap between weaker chromate touch-up pens and depot-only anodizing, to give fleet-level maintainers a stronger corrosion protection repair option for aluminum aircraft components. Maximum Phase I award across Base and Option is $315,000. Proposals are due September 23, 2026.
Executive Summary
Aerospace aluminum corrosion protection relies mainly on two coatings: anodizing, which gives superior salt-water protection but is complex and generally restricted to depot or OEM facilities, and chromate conversion coating, which is easy to apply with simple touch-up pens but offers weaker protection. When an anodized part needs a field repair, maintainers often fall back on chromate touch-up pens, which creates a weak point that's more vulnerable to corrosion than the surrounding anodized surface.
NAVAIR has already validated a third option in internal research: electrolytic conversion coating, where applying a small electrical current, several hundred milliamps per square foot, during the conversion process meaningfully improves corrosion resistance over standard chromate. The catch is that the equipment for this process currently only exists in depot chemical processing shops. This topic funds making that same electrolytic process portable enough for fleet-level touch-up use.
The requirements list reads like a checklist for a genuinely field-deployable tool: no chemical spills, environmental release, or operator exposure, simple and low-training operation, minimal hazardous waste generation, coating performance meeting or exceeding MIL-DTL-81706, no damage to the underlying aluminum through pitting or fatigue, compatibility across 2000, 6000, and 7000 series aluminum alloys, and no use of hexavalent chromium. That last point is notable given ongoing regulatory pressure on hexavalent chromium in coatings generally.
Phase I is design and feasibility: concept a portable applicator, prove it can deposit effective coatings including in tight spaces like fastener holes, and run initial corrosion and paint adhesion studies. Phase II builds and delivers a working prototype to NAVAIR, refines portability and material compatibility, and tests against MIL-DTL-81706 and MIL-PRF-8625, while the company is expected to pursue additional outside funding for fatigue testing.
Notably, this topic does not carry an ITAR restriction or classification notice, making it more accessible to companies without cleared facilities. Phase III and commercial potential are substantial, since anodizing and chromate touch-up repairs are routine maintenance across airliners, helicopters, corporate jets, and general aviation, all facing the same durability gap this technology addresses.
Funding
Phase I Base: up to $200,000
Phase I Option: up to $115,000
Maximum Phase I total (Base plus Option): $315,000
Award types: Firm Fixed Price, Basic Ordering Agreement, or Prototype Other Transaction
Phase I period: exactly 6 months Base, exactly 6 months Option
Phase II maximum: up to $2,000,000
Discretionary TABA available: up to $6,500 in Phase I, in addition to the award amount
Timeline
Proposal deadline: September 23, 2026
Submission portal: DoW SBIR/STTR Innovation Portal (DSIP)
Notifications sent approximately one week after BAA close
Phase I payments: 50% at 15 days, 35% at 90 days, 15% at 180 days, for both Base and Option
Key Requirements
Technical Volume limited to 10 pages
Minimum two-thirds of Phase I work performed by the proposing small business, in both Base and Option
No cost sharing accepted
CMMC Level 2 (Self) projected requirement
Must meet MIL-DTL-81706 corrosion performance without using hexavalent chromium
No security clearance requirement stated in the topic description
Point of Contact
Kristi DePriest, Naval Air Systems Command (NAVAIR)
navair-sbir@us.navy.mil
Frequently Asked Questions
Why not just use existing chromate touch-up pens?
Chromate touch-up pens are easy to use but offer weaker corrosion protection than anodizing, and repairing an anodized part with chromate creates a point of weakness more susceptible to corrosion.
What has NAVAIR already validated about electrolytic conversion coating?
Internal studies show applying a small electrical current, several hundred milliamps per square foot, during the coating process significantly improves corrosion resistance compared to standard chromate conversion.
Why is hexavalent chromium specifically excluded?
The process must not use hexavalent chromium, reflecting the coating industry's broader move away from that chemistry due to environmental and safety concerns.
Which aluminum alloys must this work on?
Primarily 2000, 6000, and 7000 series, though the application method must perform equally well across all aluminum alloys.
Does this topic require a security clearance?
No. The topic description does not include an ITAR restriction or classification notice.
Is there a commercial market for this technology?
Yes. NAVAIR notes commercial airliners, helicopters, corporate jets, and general aviation aircraft all rely on the same anodizing and chromate touch-up repair processes and face the same durability gap.
How much funding is available in Phase I?
Up to $200,000 for the Base and up to $115,000 for the Option, for a combined maximum of $315,000.
What is the proposal deadline?
September 23, 2026, submitted through the DoW SBIR/STTR Innovation Portal (DSIP).
