Functionally Graded Alloy Coating for Enhanced Erosion Resistance to Electromagnetic Launcher Rails

This SBIR program addresses the need for coatings for the rail components of an electromagnetic launcher, that can withstand strong mechanical, chemical, thermal and electrical forces on the rails. In the Phase I program, Faraday will demonstrate the feasibility of an environmentally benign copper-chrome functionally-graded alloy coating on copper rail specimens, that contains refractory inclusions for enhanced erosion resistance. Grading the alloy coating from 100% copper at the coating/rail interface to 100% chromium at the outer coating surface will improve the match of the thermal expansion coefficients at the coating/rail interface, for improved adhesion. The thick, functional chromium will be deposited using Faraday’s environmentally benign trivalent chromium plating process. The Phase I program will include testing via a standard 10 shot protocol to evaluate coating performance, a strategy for transitioning the technology to steel rails, and a preliminary design of a Phase II apparatus for coating full-size components. This technology demonstration will be built upon in Phase II for refinement of the coating and validation on full-scale components, transitioning to steel rails, development of prototype hardware, and extensive life cycle testing. Faraday will be supported by IAP Research through technical expertise, samples, and small scale testing and verification.