Method of coating a composite material and a coated edge of a composite structure

Abstract

A method of coating a composite material and an associated coated composite structure are disclosed to provide increased wear resistance and surface protection. The edge of the composite material may be coated so as to provide protection for the edge. A method of coating a composite material includes applying an adhesion promotion layer to the composite material. The adhesion promotion layer includes a binder paint and a plurality of metal particles within the binder paint. The metal particles may be irregularly shaped. The method also includes applying a thermal spray coating to the adhesion promotion layer. The thermal spray coating may include a twin wire arc bond coating on the adhesion promotion layer and a high velocity oxygen fuel spray coating on the twin wire arc bond coating.

Description

TECHNOLOGICAL FILED[0001]An example aspect of the present disclosure relates generally to a method of coating a composite material and an associated coated composite structure and, more particularly, a method that incorporates a technique for promoting adhesion of a thermal spray coating on a composite material as well as the resulting coated composite structure.BACKGROUND[0002]Composite materials, such as carbon-fiber reinforced composite materials, are utilized in a wide variety of applications as a result of the weight savings provided by composite parts relative to comparable metal components in combination with the improved fatigue resistance, strength and corrosion resistance relative to comparable metal components. For example, composite materials are utilized by a variety of vehicles, including aircraft, watercraft and the like, as well as buildings and other structures, to name but a few applications.[0003]Some applications that would otherwise utilize composite materials r...

AI Technical Summary

Benefits of technology

This patent is about a method for coating composite materials to increase their resistance to wear and surface protection, such as erosion. The coating is applied to the edges of the composite structure, which can be used in applications where more resistance is needed. The coating is made using a thermal spray process with a high velocity oxygen fuel spray coating and a twin wire arc bond coating. The result is a composite structure with better protection and performance.

Problems solved by technology

However, the application of metal foils to composite materials may be somewhat difficult and may consequently require substantial experience and skill on the part of a technician in order to properly install the metal foil.

Additionally, in an instance in which the metal foil is improperly applied, the composite material may have to be reworked, thereby potentially incurring significant time and expense.

Once deployed and subjected to various forces, the exposed edges of the plurality of layers of the composite material may structurally deteriorate more quickly than other portions of the composite material, thereby potentially limiting the applications in which the composite material may be deployed.

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