Abstract
In this study, an aluminium oxide-phenolic resin (Al2O3-PF) composite coating was deposited on the surface of an epoxy resin matrix composite by supersonic plasma spraying. The bond strength between the coating and matrix reached 25.64 MPa (with a maximum value of 28.1 MPa for a single test). In the oxy-acetylene ablation experiment, the mass ablative rate of the samples decreased from 0.058 to 0.033–0.035 g/s, indicating that the Al2O3-PF composite coating could effectively improve the ablation resistance of an epoxy resin matrix composite. Further, the study found that due to the stacking and aggregation of unmelted Al2O3 particles, the ablation of PF by molten Al2O3 and the polycondensation reaction between PF molecular chains, there were many pores in the coating; The continuous heat accumulation during blasting pretreatment and spraying leads to the initiation of cracks on the surface of the epoxy resin matrix and between the epoxy resin matrix and the reinforcing fibres, which reduces the structure and performance of the matrix itself; Through the bond strength test and combined with the microscopic topography analysis, it is found that the deposition main body of the Al2O3-PF composite coating is Al2O3/PF composite powder, and pure Al2O3 particles form a shot peening effect, and at the same time, the powder particles with poor deposition effect are removed by high-temperature high-speed jet scouring, thereby improving the structure and performance of the composite coating; By analysing the coating before and after ablation, it is found that the protective mechanism of Al2O3-PF composite coating improving the high temperature ablation resistance of resin matrix composites is mainly due to the remelting of Al2O3 to a certain extent during the ablation process and connecting into blocks maintaining the structural stability of the coating and ablation endotherm of PF, and outgassing creates a heat blocking effect.
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