Functionally Graded Alloy Coating for Enhanced Erosion Resistance to Electromagnetic Launcher Rails Navy SBIR FY2010.1 Sol No.: Navy SBIR FY2010.1 Topic No.: N101-086 Topic Title: Functionally Graded Alloy Coating for Enhanced Erosion Resistance to Electromagnetic Launcher Rails Proposal No.: N101-086-0348 Firm: Faraday Technology, Inc. 315 Huls Drive Clayton, Ohio 45315-8983 Contact: Timothy Hall Phone: (937) 836-7749 Web Site: http://www.faradaytechnology.com Abstract: This SBIR program addresses the need for coatings for the rail components of an electromagnetic launcher, that can withstand strong mechanical, chemical, thermal and electrical forces on the rails. In the Phase I program, Faraday will demonstrate the feasibility of an environmentally benign copper-chrome functionally-graded alloy coating on copper rail specimens, that contains refractory inclusions for enhanced erosion resistance. Grading the alloy coating from 100% copper at the coating/rail interface to 100% chromium at the outer coating surface will improve the match of the thermal expansion coefficients at the coating/rail interface, for improved adhesion. The thick, functional chromium will be deposited using Faraday's environmentally benign trivalent chromium plating process. The Phase I program will include testing via a standard 10 shot protocol to evaluate coating performance, a strategy for transitioning the technology to steel rails, and a preliminary design of a Phase II apparatus for coating full-size components. This technology demonstration will be built upon in Phase II for refinement of the coating and validation on full-scale components, transitioning to steel rails, development of prototype hardware, and extensive life cycle testing. Faraday will be supported by IAP Research through technical expertise, samples, and small scale testing and verification. Benefits: The anticipated benefit of the proposed innovative technology is the demonstration and validation of a functional coating for electromagnetic launcher rails that can withstand the extreme environmental forces imposed during firing. The primary market for this technology is the U.S. Navy, IAP Research and other Prime Contractors that are part of the development team for electromagnetic rail guns. However, as the primary coating being developed in this Phase I program includes an environmentally benign chromium deposit, this may be the first focus of additional development activities. The chrome plating market is estimated to be 15% to 20% of the $48 billion metal finishing business in the US. According to Drexel University over $1 billion in industrial and government chrome coating applications (~25%) will be replaced in the next 10 years. Additional potential applications include functionally graded coatings for components that are subject to extreme conditions of high temperature and mechanical stress. As the program progresses, and new coating systems are developed, additional potential commercial applications will emerge. Return