Search

DIGITAL LIBRARY: CAMX 2019 | ANAHEIM, CA | SEPTEMBER 23-26

Get This Paper

Cold Spray Deposition of Aluminum onto Polymer and Composite Substrates

Description

Title: Cold Spray Deposition of Aluminum onto Polymer and Composite Substrates

Authors: Po-Lun Feng, Reza Rokni, and Steven Nutt

DOI: 10.33599/nasampe/c.19.0659

Abstract: The feasibility of depositing aluminum onto thermoplastic and polymer composite substrates via cold spray (CS) of powders was investigated. Fully dense CS deposits of 7075 Al and commercial purity (CP) Al were achieved on three substrates, including polyetheretherketone (PEEK), polyetherimide (PEI), and polyetherketoneketone (PEKK) with 30 % carbon fiber, using an iterative optimization process. For CS onto thermoplastic substrates, 7075 Al deposits showed low deposition efficiencies (DEs) and low thicknesses but high adhesive strengths, while CP Al deposition resulted in high DEs and thicknesses but relatively low adhesive strengths. For CS onto PEKK with 30 % carbon fiber, deposition with N2 led to greater thicknesses (e.g., greater DEs) and adhesive strengths compared to using He. These variations are influenced by two main factors. The first factor is the differences in material properties between the coating and the substrate, such as hardness and thermal expansion coefficients. These differences can affect the depth of penetration of the impacting particles and residual stress at the coating/substrate interface. The second factor is the selected CS process parameters, i.e., CS recipe, because the first few layers and the build-up layers may require different process conditions.

References: 1. Menningen, M, Weiss, H., “Application of fracture mechanics to the adhesion of metal coatings on CFRP.” Surf. Coat. Technol. 76 (1995): 835–840. 2. Strong, A.B., Fundamentals of composites manufacturing: materials, methods and applications. MI: Society of Manufacturing Engineers, 2008. 3. Zhou, X., Chen, A., Liu, J., Wu, X., Zhang, J., “Preparation of metallic coatings on polymer matrix composites by cold spray.” Surf. Coat. Technol. 206 (2011): 132–136. 4. Li, J., Ai, Z., Zhang, Li., “Design of a neutral electro-Fenton system with Fe@Fe2O3/ACF composite cathode for wastewater treatment.” J. Hazard. Mater. 28 (2009): 18-25. 5. Bai, X.Q., Li, J., Yan, X.P., Zhao, C.H., “Application of vacuum coating technology to metallization of plastics.” J. Wuhan Univ. Technol. (Transp. Sci. Eng.) 29 (2005): 947-950. 6. Zhou, Q., Chen, H., Wang, Y., “Region-selective electroless gold plating on polycarbonate sheets by UV-patterning in combination with silver activating.” Electrochim. Acta. 55 (2010): 2542–2549. 7. Charbonnier, M., Romand, M., Goepfert, Y., Léonard, D., Bouadi, M., “Copper metallization of polymers by a palladium-free electroless process.” Surf. Coat. Technol. 200 (2005): 5478–5486. 8. Mekaru, H., Koizumi, O., Ueno, A., Takahashi, M., “Inclination of mold pattern’s sidewalls by combined technique with photolithography at defocus-positions and electroforming.” Microsystem Technol. 16 (2010): 1323–1330. 9. Voyer, J., Schulz, P., Schreiber, M., “Electrically Conductive Flame Sprayed Aluminum Coatings on Textile Substrates.” J. Therm. Spray Tech. 17 (2008): 818–823. 10. Robitaille, F., Yandouzi, M., Hind, S., Jodoin, B., “Metallic coating of aerospace carbon/epoxy composites by the pulsed gas dynamic spraying process.” Surf. Coat. Technol. 203 (2009): 2954–2960. 11. Robitaille, F., Yandouzi, M., Jodoin, B., “Production of Metallic Coatings on Polymer-Matrix Composites.” Thermal Spray 2009: Expanding Thermal Spray Performance to New Markets and Applications, Las Vegas, Nevada, May 4-7, 2009, Marple, B.R., Hyland, M.M., Lau, Y.-C., Li, C.-J., Lima, R.S., Montavon, G., Springer. 12. Rokni, M. R., Nutt, S. R., Widener, C. A., Champagne, V. K., Hrabe, R. H., "Review of relationship between particle deformation, coating microstructure, and properties in high-pressure cold spray." Journal of thermal spray technology 26(6) (2017): 1308-1355. 13. Zhang, D., Shipway, P., McCartney, D., “Cold Gas Dynamic Spraying of Aluminum: The Role of Substrate Characteristics in Deposit Formation.” J. Therm. Spray Tech. 14 (2005): 109–116 14. Burlacov, I., Jirkovský, J., Kavan, L., Ballhorn, R., Heimann, R., “Cold gas dynamic spraying (CGDS) of TiO2 (anatase) powders onto poly(sulfone) substrates: Microstructural characterisation and photocatalytic efficiency.” J. Photochem. Photobiol. A 187 (2007): 285–292. 15. Lupoi, R., Oneill, W., “Deposition of metallic coatings on polymer surfaces using cold spray.” Surf. Coat. Technol. 205 (2010): 2167–2173. 16. Affi, J., Okazaki, H., Yamada, M., Fukumoto, M., “Fabrication of aluminum coating onto CFRP substrate by cold spray.” Mater. Trans. 52(9) (2011): 1759-1763. 17. Ganesan, A., Affi, J., Yamada, M., Fukumoto, M., “Bonding behavior studies of cold sprayed copper coating on the PVC polymer substrate.” Surf. Coat. Technol. 207 (2012): 262–269. 18. Ganesan, A., Yamada, M., Fukumoto, M., “Cold Spray Coating Deposition Mechanism on the Thermoplastic and Thermosetting Polymer Substrates.” J. Therm. Spray Tech. 22 (2013): 1275–1282. 19. King, P.C., Poole, A.J., Horne, S., Nys, R.D., Gulizia, S., Jahedi, M.Z., “Embedment of copper particles into polymers by cold spray.” Surf. Coat. Technol. 216 (2013): 60–67. 20. Stenson, C., McDonnell, K.A., Yin, S., Aldwell, B., Meyer, M., Dowling, D.P., et al., “Cold spray deposition to prevent fouling of polymer surfaces.” Surf. Eng. 34 (2016): 193–204. 21. Bortolussi, V., Borit, F., Chesnaud, A., Jeandin, M., Faessel, M., Figliuzzi, B., et al., “Cold spray of metal-polymer composite coatings onto carbon fiber-reinforced polymer (CFRP).” Thermal Spray 2016: Proceedings from the International Thermal Spray Conference, Shanghai, P.R. China, May 10-12, 2016 ASM International. 22. Che, H., Vo, P., Yue, S., “Metallization of carbon fibre reinforced polymers by cold spray.” Surf. Coat. Technol. 313 (2017): 236–247. 23. Che, H., Chu, X., Vo, P., Yue, S., “Metallization of Various Polymers by Cold Spray.” J. Therm. Spray Tech. 27 (2017): 169–178. 24. Sabard, A., Albassam, A., Chadha, S., Hussain, T., “Cold Spraying of Metallic Powders onto Polymeric Substrates: Influence of Gas Preheating Temperature on the Coating Deposition.” Thermal Spray 2018: Proceedings from the International Thermal Spray Conference, Orlando, FL, May 7-10, 2018, ASM International. 25. Che, H., Chu, X., Vo, P., Yue, S., “Cold spray of mixed metal powders on carbon fibre reinforced polymers.” Surf. Coat. Technol. 329 (2017): 232–243. 26. Che, H., Yue, S., Vo, P., “Investigation of Cold Spray on Polymers by Single Particle Impact Experiments.” Thermal Spray 2018: Proceedings from the International Thermal Spray Conference, Orlando, FL, May 7-10, 2018, ASM International. 27. Chen, Chaoyue, Xie, Xinliang, Xie, Yingchun, Yan, Xincheng, Huang, Chunjie, Deng, Sihao, Ren, Zhongming, and Liao, Hanlin, "Metallization of polyether ether ketone (PEEK) by copper coating via cold spray." Surface and Coatings Technology 342 (2018): 209-219. 28. CES EduPack. Granta Design Ltd., 10 May 2018 <https://grantadesign.com/education/ces-edupack/> 29. Wang, Q., Birbilis, N., and Zhang, M.X., “Interfacial structure between particles in an aluminum deposit produced by cold spray.” Mater. Lett. 65(11) (2011): 1576-1578. 30. Rokni, M.R., Widener, C. A., Champagne, V. K., Crawford, G. A., and Nutt, S. R., “The effects of heat treatment on 7075 Al cold spray deposits.” Surf. Coat. Technol. 310 (2017): 278-285. 31. ASTM Standard D4541-17, 2017, “Standard test method for pull-off strength of coatings using portable adhesion testers”, ASTM International. 32. Suo, X., Yin, S., Planche, M.-P., Liu, T., and Liao, H., “Strong Effect of Carrier Gas Species on Particle Velocity During Cold Spray Processes.” Surf. Coat. Technol. 268 (2015): 90-93. 33. Arabgol, Z., Assadi, H., Schmidt, T., Gärtner, F., Klassen, T., “Analysis of Thermal History and Residual Stress in Cold-Sprayed Coatings.” J. Therm. Spray Tech. 23 (2013): 84–90. 34. Li, C.J. and Li, W.Y., “Deposition Characteristics of Titanium Coating in Cold Spraying.” Surf. Coat. Technol. 167 (2003): 278-283. 35. Goldbaum, D., Ajaja, J., Chromik, R.R., Wong, W., Yue, S., Irissou, E. and Legoux, J.G., “Mechanical Behavior of Ti Cold Spray Coatings Determined by a Multi-scale Indentation Method.” Mater. Sci. Eng. A 530 (2011): 253-265. 36. Bolelli, G., Bonferroni, B., Koivuluoto, H., Lusvarghi, L., and Vuoristo, P., “Depth-Sensing Indentation for Assessing the Mechanical Properties of Cold-Sprayed Ta.” Surf. Coat. Technol. 205 (2010): 2209-2217.37. Li, C.J. and Li, W.Y., “Microstructure Evolution of Cold-Sprayed Coating During Deposition and Through Post-spraying Heat Treatment.” Trans. Nonferrous Met. Soc. China 14 (2004): 49-54. 38. Hussain, T., “Cold Spraying of Titanium: A Review of Bonding Mechanisms, Microstructure and Properties” Key Eng. Maters. 533 (2013): 53-90. 39. Rokni, M.R., Widener, C.A., Champagne, V.K., and Crawford, G.A., “Microstructure and Mechanical Properties of Cold Sprayed 7075 Deposition During Non-isothermal Annealing.” Surf. Coat. Technol. 276 (2015): 305-315. 40. Rokni, M.R., Widener, C.A., Crawford, G.A., and West, M.K., “An Investigation into Microstructure and Mechanical Properties of Cold Sprayed 7075 Al Deposition.” Mater. Sci. Eng. A 625 (2015): 19-27.

Conference: CAMX 2019

Publication Date: 2019/09/23

SKU: TP19-0659

Pages: 15

Price: $30.00

Get This Paper