Direct Deposition of Durable Coating Material onto Navy Components Via Quasi-Equilibrium Plasma

Currently utilized industrial coating techniques can be encumbered with processing variables, ultimately presenting risks to the operator. Additionally, touch-time inefficiencies, potential chemical hazards, and environmental concerns all contribute to the high cost and time requirements of coating processes within the manufacturing pipeline. Thermal plasma coating systems have been successfully implemented into the industry for the deposition of coating materials; however, these technologies have required low pressure (typically near-vacuum) environments to operate in. These low-pressure systems are inherently costly to operate and often require expensive modules to reach and sustain low pressure environments. To overcome these concerns, AAPlasma proposes the development of a quasi-equilibrium Gliding Arc Plasma Coating Deposition System (GAP-CDS). Ongoing developments in atmospheric pressure plasma treatment science show improvements in powder, droplet, and nanoparticle deposition. Gas-phase plasma catalysis can produce and control chemical reactions in gas phase and on the particle surface. By increasing the level of control over individual raw feedstock materials (along with other factors such as individual carrier gas flow rates), GAP-assisted coating technology can improve the quality, availability, and cost-effectiveness of applying durable and resistant coatings. GAP technology is sufficiently mature and has been demonstrated numerous times for treatment of various fluid/gas mixtures. Specific to this proposal, we are employing the combination of two robust and stable 500-Watt GAP systems to achieve cost-effective and rapid coating. There are no moving parts and the strong internal cooling allows this system to operate stably and without maintenance for months. Approved for Public Release | 22-MDA-11215 (27 Jul 22)