Any ideas for a very rigid, hard coating that can be applied by conventional methods? the coating would also need to be fairly high in viscosity to avoid saturating the core material. The application is a propeller blade 7" long by 1" wide and .040" thick. To put the loads in perspective each blade produces about 25g of thrust at 1000 rpm. The current design uses 1 ply of spread tow unidirectional carbon fiber/ epoxy (.002" cured thickness) on either side with a balsa core in the center. this nets a blade that weighs 1.0g and is more rigid, stronger and durable than it needs to be. A coating(.002-.004" thick) with similar tension, compression and modulus of the laminate capable of the loads mentioned above would be ideal.I would assume if such a coating existed it would be very brittle and thats fine. The hopes are the end result would be a slight reduction in weight and a less intensive process for making them.
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