Microstructure and mechanical properties of thermally sprayed silica/nylon nanocomposites

High-velocity oxyfuel thermal spray processing was used to produce ceramic/polymer (silica/nylon) nanocomposite coatings, By optimizing spray parameters such as nozzle design, spray distance, oxygen-to-fuel ratio, powder feed position, and substrate cooling, dense coatings with relatively uniform particulate distribution could be achieved, Compared to pure nylon coatings, scratch resistance improved by 30% and wear resistance by 50%. The surface chemistry of the silica filler affected the final coating properties, Silica particles with a hydrophobic (methylated) surface resulted in better mechanical properties than those with a hydrophilic (hydroxylated) surface.