Polymers reinforced with nanoscopic ceramic particles exhibit dramatic improvements in the wear properties of protective polymeric barrier coatings. Work with nylon 11/silica materials showed that the high velocity oxy-fuel [HVOF] technique can be used to spray 5-15 vol. % nanoreinforced coatings that exhibit improved scratch resistance, modulus etc., and decreased permeability compared to pure polymer coatings. The properties were found to depend on reinforcement volume fraction, reinforcement type, polymer powder size and crystallinity. Background on thermal spraying of polymers and polymer/nanoceramic composites, as well as important mechanical properties arising from the nanoscopic reinforcement will be reviewed. Recent work on crystallinity development in sprayed, reinforced nylon 11, pure and filled polycarbonate [PC] (an amorphous matrix material) and on multiple scales of ceramic reinforcement will be discussed. Improved properties have again been observed in each case.
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