Abstract: A system and method for coating a foil mesh with a no-chrome conversion coating is provided, wherein the system includes a solution tank, wherein the solution tank defines a tank cavity for containing a conversion coating solution, wherein the conversion coating solution comprises at least one of 5% butyl benzotriazole sodium salt and 7% alodine 5200. The system further includes a reel/roller system configured to cause the foil mesh to be disposed within the conversion coating solution for a predetermine period of time.

Abstract: An anti-icing/de-icing system for an airfoil structure having multiple layers is provided and includes a thermal article, wherein the thermal article is embedded within the airfoil structure to be located between the multiple layers. The thermal article includes a first terminal end, a second terminal end and a thermal expanded mesh material which connects the first terminal end with the second terminal end, and wherein the thermal expanded mesh material is configured to have at least one predetermined resistance between the first terminal end and the second terminal end.

Abstract: A system and method for coating a foil mesh with a no-chrome conversion coating is provided, wherein the system includes a solution tank, wherein the solution tank defines a tank cavity for containing a conversion coating solution, wherein the conversion coating solution comprises at least one of 5% butyl benzotriazole sodium salt and 7% alodine 5200. The system further includes a reel/roller system configured to cause the foil mesh to be disposed within the conversion coating solution for a predetermine period of time.

Abstract: A system and method for coating a foil mesh with a non-chromate conversion coating is provided, wherein the method includes expanding a foil web into a nonwoven screen, processing the nonwoven screen to remove grease and other surface contaminants, flattening the nonwoven screen to a thickness of between about 0.002 inches and about 0.006 inches to create a flattened nonwoven screen, annealing the flattened nonwoven screen to create a foil mesh, associating the foil mesh with a system for coating a foil mesh, wherein the system includes a solution tank having a tank cavity containing a conversion coating solution, bathing the foil mesh within the conversion coating solution for approximately 30 seconds to create a coated foil mesh and curing the coating foil mesh for approximately 18 hours to create an expanded foil mesh.

Abstract: A system and method for coating a foil mesh with a non-chromate conversion coating is provided, wherein the method includes expanding a foil web into a nonwoven screen, processing the nonwoven screen to remove grease and other surface contaminants, flattening the nonwoven screen to a thickness of between about 0.002 inches and about 0.006 inches to create a flattened nonwoven screen, annealing the flattened nonwoven screen to create a foil mesh, associating the foil mesh with a system for coating a foil mesh, wherein the system includes a solution tank having a tank cavity containing a conversion coating solution, bathing the foil mesh within the conversion coating solution for approximately 30 seconds to create a coated foil mesh and curing the coating foil mesh for approximately 18 hours to create an expanded foil mesh.