Super High Temperature Erosion and Wear Resistant Ceramic Rubber™ Coatings

Period of Performance: 04/14/2006 - 08/14/2007

$100K

Phase 1 SBIR

Recipient Firm

Nanosonic, Inc.
158 Wheatland Drive Array
Pembroke, VA 24136
Principal Investigator

Abstract

NanoSonic has developed revolutionary nanostructured, inorganic/organic hybrid Metal Rubber and Ceramic Rubber coatings. Specifically, ultra-lightweight ( 450 C, 842 F) and abrasion / wear resistance with excellent adhesion to metal and PMC substrates with complex shapes are offered. Metal Rubber is fabricated via layer-by-layer, molecular self-assembly, which enables thickness and placement control over multiple constituents for true nanostructured multifunctionality (nm scale). Opposed to PVD, NanoSonic s patented self-assembly process incorporates high temperature, advanced polymers within ceramic or metal coatings and offer controlled thickness (nm thin up to mm thick) on substrates up to 24 square inches. Metal Rubber is a novel nanocomposite formed in situ, by chemically reacting monolayers of nanosized components, thereby eliminating residual stress (overcoming mismatched CTEs) and debonding between each component and the substrate. Ductile Metal Rubber coatings do not crack or spall upon intact due to incorporation of polymers. Hardness of up to 1 GPa has been demonstrated by replacing the metal with ceramics for our Ceramic Rubber coatings, which would be optimized for aircraft engine components such as stator vanes. Sand/grit erosion resistance would be verified at UDRI and with assistance from Lockheed Martin Aeronautics.