Friction-Stir-Additive and Plasma-Electrolytic-Oxidation Coating Technologies for Penetration Resistance

The U.S. Army requires additive manufacturing (AM) techniques that can repair and retrofit structures to improve ballistic survivability. Current AM processes have low deposition rates, are constrained by environmental chambers, and are not readily scalable for large-size production. The goal of this STTR topic is to develop a rapid-deposition ballistic-resistant-coating for metal panels. NanoCoatings, along with South Dakota School of Mines & Technology, will demonstrated two unique enhanced armor coating technologies: 1) Friction-Stir-Additive (FSA) deposition of graded-composition hard-ceramic particles within a ductile 5083 Al matrix and 2) Plasma Electrolytic Oxidation (PEO) of 5083 Al panels to convert the outer surfaces into hard crystalline aluminum-oxide surfaces impregnated with even harder carbide or boride particles. This PEO method will be applied to multiple panels to provide a multilayer configuration consisting of alternating hard and soft (5083 Al core) layers for projectile disruption and energy absorption. Deposition rates for the FSA technique will be quantified, while the PEO approach will result in ballistic patches that can be applied to damaged steel structures. Microstructure analysis, adhesion, and hardness measurements will be taken on prototype panels, with larger (e.g., 30.5 cm square) panels provided to the U.S. Army as deliverable items for ballistic testing.