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.

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Conference: CAMX 2019

Publication Date: 2019/09/23

SKU: TP19-0659

Pages: 15

Price: $30.00