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.

That which is claimed: 
     
         1 . A method of coating a composite material, the method comprising:
 applying an adhesion promotion layer to the composite material, wherein the adhesion promotion layer comprises a binder paint and a plurality of metal particles within the binder paint; and   applying a thermal spray coating to the adhesion promotion layer.   
     
     
         2 . A method according to  claim 1  wherein the plurality of metal particles comprise a plurality of irregularly shaped metal particles. 
     
     
         3 . A method according to  claim 2  further comprising producing the irregularly shaped metal particles by water atomization. 
     
     
         4 . A method according to  claim 1  wherein applying an adhesion promotion layer comprises applying the adhesion promotion layer to at least an edge of the composite material, and wherein applying the thermal spray coating comprises applying the thermal spray coating to the adhesion promotion layer on at least the edge of the composite material. 
     
     
         5 . A method according to  claim 4  further comprising processing the edge of the composite material such that the edge of the composite material has a rounded or beveled profile prior to application of the adhesion promotion layer. 
     
     
         6 . A method according to  claim 1  further comprising removing some of the binder paint prior to applying the thermal spray coating so as to expose at least a portion of the metal particles. 
     
     
         7 . A method according to  claim 1  wherein the plurality of metal particles have a size between 5 μm and 90 μm. 
     
     
         8 . A method according to  claim 1  wherein the plurality of metal particles comprises steel particles. 
     
     
         9 . A method according to  claim 1  wherein applying a thermal spray coating comprises applying a high velocity oxygen fuel spray coating. 
     
     
         10 . A method according to  claim 9  wherein applying a thermal spray coating further comprises applying a twin wire arc bond coating to the adhesion promotion layer prior to applying the high velocity oxygen fuel spray coating to the twin wire arc bond coating. 
     
     
         11 . A method of coating a composite material, the method comprising:
 applying an adhesion promotion layer to the composite material, wherein the adhesion promotion layer comprises a binder paint and a plurality of irregularly shaped metal particles within the binder paint;   applying a twin wire arc bond coating to the adhesion promotion layer; and   applying a high velocity oxygen fuel spray coating to the twin wire arc bond coating.   
     
     
         12 . A method according to  claim 11  further comprising producing the irregularly shaped metal particles by water atomization. 
     
     
         13 . A method according to  claim 11  further comprising removing some of the binder paint prior to applying the twin wire arc bond coating so as to expose at least a portion of the metal particles. 
     
     
         14 . A method according to  claim 11  wherein applying an adhesion promotion layer comprises applying the adhesion promotion layer to at least an edge of the composite material. 
     
     
         15 . A coated composite structure comprising:
 a composite material;   an adhesion promotion layer on the composite material, wherein the adhesion promotion layer comprises a binder paint and a plurality of metal particles within the binder paint; and   a thermal spray coating on the adhesion promotion layer.   
     
     
         16 . A coated composite structure according to  claim 15  wherein the plurality of metal particles comprise a plurality of irregularly shaped metal particles. 
     
     
         17 . A coated composite structure according to  claim 15  wherein at least some of the metal particles are exposed through the binder paint so as to engage the thermal spray coating. 
     
     
         18 . A coated composite structure according to  claim 15  wherein the composite material includes an edge, and wherein the adhesion promotion layer is on the edge of the composite material. 
     
     
         19 . A coated composite structure according to  claim 15  wherein the thermal spray coating comprises a high velocity oxygen fuel spray coating. 
     
     
         20 . A coated composite structure according to  claim 19  wherein the thermal spray coating further comprises a twin wire arc bond coating on the adhesion promotion layer with the high velocity oxygen fuel spray coating on the twin wire arc bond coating.