AeroPel NPL APW Series Corrosion Protection for Aviation

AeroPel is a nanocomposite protective layer (NPL) developed by Oceanit to protect aviation airframes and aerospace assets such as ground support equipment from corrosion and surface degradation.

The water-based formulation forms a transparent, surface finish that repels water, oils, and other fluids and works in a wide variety of demanding environments.

AeroPel imparts a low-surface-energy finish that causes moisture and fluids to bead up and roll off rather than wetting and penetrating into a substrate. By preventing long-term contact between corrosive fluids and the metal surface, it interrupts the corrosion process. Additionally, this repellent chemistry reduces buildup of dirt and fouling, meaning parts are both easier to clean and can go without maintenance longer.

AeroPel addresses chronic corrosion issues that drive increased maintenance costs and aircraft downtime. AeroPel offers corrosion protection, helps extend asset life, reduce unscheduled repairs, and improve operational readiness.

AeroPel offers several core performance benefits for aviation operators and maintainers:

• Corrosion protection for airframes, fuel tanks, environmental control system (ECS) ducting, and ground support equipment (GSE)
• “Omniphobicity” means chemically compatible with fuels, and hydraulic fluids, unlike many “superhydrophobic coatings”
• Reduced surface friction and improved flow in airflow components
• Suitable for temperatures between -40°C – 123°C
• Transparent, semi‑gloss finish that allows for markings and underlying coatings to remain visible

As an add-on protection against corrosion, AeroPel’s omniphobic surface prevents corrosive fluids from wetting and attacking metallic substrates, thereby slowing or stopping corrosion initiation. This reduction in corrosion damage translates into fewer repairs, less time in maintenance, and lower lifecycle costs for fleets dealing with harsh, high-humidity, or coastal conditions.

Unlike traditional CICs, AeroPel forms a bonded nanocomposite layer that is more durable and less prone to wash-off or depletion. This lighter, longer-lasting protection can reduce CIC weight on aircraft, cut fuel consumption, and lower emissions while maintaining or improving corrosion performance.

The AeroPel APC Ice Protection Series is an icephobic variant designed to prevent ice nucleation and dramatically reduce ice adhesion on treated surfaces. It is not currently commercially available, but is in active development and field trial testing. Please contact Oceanit for specific inquiries about this product.

AeroPel is engineered for a broad range of aviation substrates, including aluminum and other metallic airframe structures, ECS ducting, and selected polymers and ceramics. It can be used on aircraft exteriors, internal cavities, fuel tank components, and ground support equipment exposed to corrosive and erosive environments.

AeroPel NPL is designed for stability under high temperatures and harsh UV exposure typical of aviation environments. It resists fuels, hydraulic fluids, and abrasion, providing durable protection even in high-cycle, high-stress operational conditions. Contact Oceanit about your specific operational requirement for a more detailed analysis.

Yes, Oceanit has partnered with Lockheed Martin to evaluate and deploy AeroPel NPL for U.S. Department of Defense aircraft and ground support equipment. AeroPel has also undergone testing by the Air Force Research Laboratory and the U.S. Army Corps of Engineers CRREL for its icephobic and corrosion-performance characteristics.

AeroPel was developed by Oceanit under the Small Business Innovation Research program (SBIR), America’s Seed Fund. Successful awards working with the Air Force, Army, and Navy have all allowed for Oceanit to successfully transition AeroPel from a concept to a commercially available offering now being used by multiple aviation partners. Oceanit is a Mind-to-Market company focused on developing standalone advanced materials, AI, and engineering solutions for aerospace, defense, energy, and industrial sectors. The AeroPel portfolio reflects Oceanit’s broader expertise in functional coatings and surface treatments designed for harsh operational environments.