Erosion and impact resistant thermal spray coatings for fiber-reinforced polymer applications

This Small Business Innovation Research Phase I objective is to develop a cavitation resistant and impact resistant coating system on Fiber Reinforced Polymer (FRP) substrates. The use of FRP materials have many benefits, including stringent fabrication tolerance at reduced procurement cost, hydrodynamic efficiency leading to reduced life-cycle costs, cavitation, radiated noise and weight. Efforts have demonstrated improvements in the cavitation erosion resistance of FRPs, although their improved performance still remains well below traditional metallic materials. Also, although prior research has shown oxidation can be slowed when metallic or ceramic coatings are applied onto FRP’s, there remains a need for cavitation-resistant and impact-resistant coatings that protect FRP’s from cavitation as well as eroding particulates. A multifunctional composite material that provides both good structural properties and high resistance to cavitation and erosion from a multiple of sources would allow for FRP’s to be used in marine applications. Therefore, this Phase I effort is to develop affordable cavitation resistant and impact resistant coating systems (materials and processes) that are compatible with candidate FRP’s.