The high velocity oxy-fuel (HVOF) combustion spray technique previously has been shown to be an excellent solution for depositing nano-reinforced thermoplastic polymer coatings. Dense polymer coatings can be produced regardless of ceramic particle size with little change in the spray parameters. Composite powders with multiple scales of silica reinforcement, ranging from 12 nm to 100 µm, have been created. Preliminary testing was begun using melt processing. The multiple scales have shown improved scratch resistance relative to single-scale reinforcements.

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