目的 解决底/面漆涂层在铝合金与复合材料基材表面经常出现剥离、起泡、开裂等缺陷问题。方法 通过对问题涂层部件的结构设计合理性分析，指出了封闭式蒙皮结构部件出现的设计缺陷。对铝合金与复合材料的加工工艺进行了分析，用对比试验的方法，验证了铝合金阳极氧化处理工艺所生成的保护膜对涂层性能的影响。通过改进表面前处理工艺，验证了复合材料表层残留的脱模剂是影响涂层附着力的主要原因。以改善涂层应力变化适应能力为目的，调整了涂料韧性配方，涂覆不同的基材和相关结构部件，用可模拟产品试验考核状态的“温度冲击＋振动＋湿热”联合加载试验方法，验证了设计与工艺改进后的涂层性能。结果 合理设计通气孔后，消除了封闭式蒙皮结构部件内部气体的膨胀效应，改进铝合金与复合材料表面前处理工艺和涂料韧性后，涂层不再出现起层开裂现象。结论 封闭式蒙皮结构部件应设置内外通气工艺孔，彻底清除复合材料表面脱模剂渗透层和铝合金表面的阳极氧化膜，选用韧性好的涂料体系，能够有效提升铝合金与复合材料组合构件表面涂层的环境适应性能。

The work aims to remove defects usually present on primer/finish coatings including peeling, blistering, cracking on the surface of aluminum alloy and composite material substrate. The designing defects of the closed thin-gauge skin structural components were figured out based upon structural design rationality analysis of defective coating components. By analyzing process technique for aluminum alloy and composite materials, effects of protective layer generated by aluminum alloy anodizing on coating properties were validated in contrast test method. By improving the surface pretreatment technology, release agent left over the composite materials was verified to be main factor affecting coating adhesion. The coating toughness formula was adjusted and coated on different substrates and relevant structural components to improve adaptability of coating to stress changes. Coating properties featuring in improved design and process were verified in combined loading test method “thermal shock+vibration+shock+dampness-heat”, which could be used to simulate testing state of the product. The coating was completely free from delamination and cracking after venthole was designed reasonably, gas expansion effect in the closed thin-gauge skin structural components was eliminated, and coating toughness and surface pretreatment of aluminum alloy and composite materials were improved. Closed thin-gauge skin structural components shall be equipped with venthole inside and outside. Complete removal of surface release agent pervious layer on composite materials and anodic oxide film on aluminum alloy, and selection of coating system exhibiting good toughness can improve environmental adaptability of surface coatings on aluminum alloy and composite material composite components.