Metallic Coatings for Structural Enhancement of Polymers and Composites for Reduced Weight Missile Structure (METCOAT)

The Concepts to Systems, Inc. (C2Si) team, after successfully demonstrating feasibility of coating plastics with metals by the cold spray (CS) process in Phase I, is proposing to mature the technology in Phase II to manufacture and test structural support components. The C2Si team will supplement initial material selection based on qualitative comparison of design attributes in Phase I with a material that may be more desirable for applications selected in Phase II. A systematic CS process parametric study will be undertaken in Phase II to improve process efficiency and enhance structural properties of the resulting parts. Process parameters will be also adjusted to provide control over coating thickness. Our team will also create CS processing recipes to coat curved and angle surfaces and to coat holes by an innovative two-step process. In addition to CS process optimization and characterization of deposits, C2Si will perform numerical analysis at material constitutive and structural component levels. Static and dynamic structural testing at coupon and component level will be performed as well, supplemented with environmental testing representative of the component usage environment in intended applications. Finally, prototype CS processed components will be compared with metallic components to demonstrate weight savings and replacement value.