Improving the adhesion of wear-resistant coatings on aerospace polymer composites

Fiber-reinforced polymer composites are increasingly used in aerospace for weight-sensitive applications. However, they are subjected to degradation from the erosive forces of solid particles and water droplets. This degradation results in a decreased service life of composite components and increased repair costs.

Thermal-sprayed coatings have been developed to protect polymer composites. An issue is the thermal and mechanical damage to the composite surface by the thermal-sprayed particles. Another issue is the adhesion of coating because of the low wettability of polymer surface to liquid metal and ceramic and different atomistic properties between substrate and coating material. A possible solution to both issues is the use of a bond coat deposited by a “softer “ technique than thermal spraying.

This study deals with the deposition of bond coat by various alternative methods and topcoat by plasma spraying. The interfaces of the duplex coatings and, adhesion of coating are examined.