Polymer coatings are being used in a growing range of applications, including passivation, wear, and chemical resistance. The primary technical challenge in the practical use of nanocomposite coatings is achievement of uniform dispersions of the nanoparticulates within the polymer matrix. The research objectives are: (1) develop an understanding of the complex nanoscale microstructural development in both the matrix and the overall composite as a function of reinforcement composition, dispersion/distribution, loading, morphology and surface chemistry as well as spray parameters; (2) understand the role of particulate surface chemistry in improving the dispersion of the reinforcement, the moisture and gas permeability, and the corrosion resistance; (3) optimize dispersion of the reinforcing phase within the composite coatings through manipulation of matrix and particle properties and deposition parameters, including matrix composition, particulate surface chemistry and morphology, and spray parameters; and (4) develop a property database of the effects of reinforcement content and surface chemistry, spray parameters and matrix structure on the corrosion/permeability properties. The scratch resistance and permeability can both be improved significantly through the addition of nanoparticulate ceramic reinforcements to the polymer matrix from the outcomes of the research activities. This would then be used to develop optimized composite coatings suitable for use as commercial corrosion and moisture barriers.
