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Epoxy zinc-rich coatings are widely used in harsh environments because of the long-lasting cathodic protection of steel surfaces. The purpose of this paper is to use flake zinc powder instead of the commonly used spherical zinc powder to reduce the zinc powder content.

In this paper, the authors have prepared an anticorrosive zinc-rich coating using a flake zinc powder instead of the conventional spherical zinc powder. The optimal dispersion of scaly zinc powder in zinc-rich coatings has been explored by looking at the surface and cross-sectional morphology and studying the cathodic protection time of the coating.

The final epoxy zinc-rich coating with 35 Wt.% flake zinc powder content was prepared using sand-milling dispersions. It has a similar cathodic protection time and salt spray resistance as the 60 Wt.% spherical zinc-rich coating, with a higher low-frequency impedance modulus value.

This study uses flake zinc powder instead of the traditional spherical zinc powder. This reduces the amount of zinc powder in the coating and improves the corrosion resistance of the coating.

This paper aims to explore a structural optimization method to achieve the lightweight design of an aviation control stick part manufactured by laser powder bed fusion (LPBF) additive manufacturing (AM). The utilization of LPBF for the fabrication of the part provides great freedom to its structure optimization, further reduces its weight and improves its portability.

The stress distribution of the model was analyzed by finite element analysis. The material distribution path of the model was optimized through topology optimization. The structure and size of the parts were designed by applying honeycomb structures for weight reduction. The lightweight designed control stick part model was printed by LPBF using AlSi10Mg.

The weight of the control stick model was reduced by 32.64% through the optimization method using honeycomb structures with various geometries. The similar stress concentrations of the control stick model indicate that weight reduction has negligible effect on its mechanical strength. The maximum stress of the lightweight designed model under loading is 230.85 MPa, which is 61.81% larger than that of the original model. The lightweight control stick part manufactured by LPBF has good printability and service performance.

A structural optimization method integrating topology, shape and size optimization was proposed for a lightweight AlSi10Mg control stick printed by LPBF. The effectiveness of the optimization method, the printability of the lightweight model and the service performance of LPBF-printed AlSi10Mg control stick was verified, which provided practical references for the lightweight design of AM.