Cold Electrostatic Deposition of Materials on Heat Sensitive and Other Substrates

The proposed process will provide the capability to deposit metal coatings onto heat sensitive composite substrates. The process eliminates problems associated with thermal spray technologies, including oxidation, contamination and overheating of the coating and substrate materials. This process enables dense, adherent coatings to be applied to low temperature composite materials for wear, corrosion and temperature resistant surfaces. The innovation employs a proprietary method to propel molten metallic and other powders to a substrate where they are deposited to form protective coatings. The process significantly reduces the heat imparted to the substrate surface compared to conventional thermal spray technologies. Phase I will examine the feasibility of the process to coat temperature sensitive materials with metallic materials, and will evaluate the strength and adhesion properties of the deposited coating. A prototype system will be constructed and tested. Phase II R/R&D will examine the application of desirable coatings and their properties, and will develop systems capable of coating large structures at remote sites. Phase 111 will implement a commercialization plan to market and sell coating systems to composite and equipment manufacturers.