An important factor in the process of formation of a metal-polymer coating is the effect of a high-temperature gas jet on the "coating-substrate" system, as the jet favours penetration and spread of a polymeric material over the surface of the substrate. It is this factor that makes this form of thermal spraying radically different from spraying metallic coatings. On the other hand, excessive heating of the surface can lead to oxidation and degradation of the polymeric component. Therefore, thermal phenomena taking place during the formation of thermal sprayed metal-polymeric coatings, i.e. the level and distribution of temperatures through the thickness of a coating were analysed. Based on the results of mathematical modeling, recommendations for the thermal spraying of metal-polymeric coatings (heat source speed, spraying distance, flow rate of working gases, etc.) were developed.
In thermal spraying of metal-polymer coatings, the processes of polymers oxidation and destruction can have special features, as the temperature of heating of the filler particles can significantly exceed the temperature of destruction of the polymer binder. Hence, the need to study the features of the process of formation of thermal sprayed coatings from filled polymers and their physico-chemical, mechanical and service properties. This paper describes the influence of a filler composition and conditions of flame spraying on a structure and mechanical properties of composite polymer coatings. It is observed that addition of 5-10 vol. % of Fe-Ni-B alloy powder to low-pressure polyethylene polymer matrices, improves the wear resistance of thermal sprayed coatings 1.2-1.3 times under the conditions of gas-abrasive wear, compared to purely polymer coating, owing to the combination of the higher hardness of the coating with the high damping properties of the polymer matrix.
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