I have no doubt that a lot of experimentation has been done using coatings on GA airplanes and to the extent that a coating would work, the main problem that I see is degradation of the coating from UV and erosion. A coating would likely have to be restored regularly and would be likely too expensive for most tightwad GA pilots.
The other thing is that ...
VFE is calculated for full flap extension, so the loads with just one notch of flaps are much smaller than the limit loads which determine VFE. It is very unlikely that this results in structural damage. Having said that, there is really no reason to exceed VFE with flaps down.
There are two types of damage that could result from flying too fast with flaps ...
Unless a different speed is explicitly noted for partial flap extension, Vfe pertains to extending the flaps any amount. (For example, the C-172RG has a Vfe of 130 KIAS to 10º flaps, 100 KIAS beyond 10º flaps. Not so for the PA28s.)
You can't transfer an approval so yes, you need to get a new one. From AFSP's Application Guide:
TSA cannot transfer your training event request from one flight training provider to another flight training provider. TSA approval is
valid only for the flight training provider listed on the training
You may desire to build more ...
No, FSDO's do not issue the plastic cards. Your only option is to wait.
Processing time takes quite a while. For example, it is November 13 and the FAA is currently processing applications that were submitted on October 3. The process to actually receive your plastic license can take from 30 days (unlikely) to over 3 months. I think on average the time ...
No, sorry. They don’t have the device at the FSDO that would produce a plastic card.
If you want to see the page that shows what date they are currently processing for, click here.
Unfortunately it’s typically around 6-8 weeks.