Developing Technologies for Thermal Spraying Composite Materials

This thesis details the technological development of a lightweight, corrosion and wear-resistant marine hydraulic cylinder actuator. A novel multi-layered structure—glass fibre reinforced polymer, titanium sleeve, and tungsten-carbide nickel-chromium thermal spray coating was manufactured using high-velocity oxy-fuel thermal spray with advanced cooling techniques.

The prototype was developed from conceptual design to a fully functional device, demonstrating structural integrity, dimensional stability, and excellent surface performance under hydrostatic pressure of 30 mega-pascals and 200,000 load cycles. The composite prototype achieved a 63 per cent weight reduction compared to a conventional Monel K-500 rod, offering an industry-ready solution for demanding marine applications.