Title: Cold Spray Deposition of Titanium Onto Carbon Fiber Reinforced Polymer with Hybrid Polymer-Metal Bond Layer

Authors: Po-Lun Feng, Alexander Li, Bo Jin, Steven Nutt

DOI: 10.33599/nasampe/c.22.0071

Abstract: The feasibility of depositing Ti onto carbon fiber reinforced polymers (CFRPs) via cold spray (CS) was investigated. Dense and adherent CS Ti coatings were deposited onto CFRP with an epoxy-Al (woven Al wire reinforced) bond layer. To avoid erosion of the CFRP and achieve cold-weld of impinging particles, a bond layer (BL) is required. For a given cold spray particle size, bond layer suitability depended primarily on the mesh opening size and wire diameter of the metal reinforcement. Adhesion of cold-sprayed coating was determined by the BL-CFRP, particle-BL, and particle-particle bonding. Particle-BL bonding depended on metallic bonding, mechanical interlocking, and intermixing between the CS Ti particles and the bond layer. The first pass of cold spray partially eroded the bond layer, and the second pass filled the eroded regions, which led to interlocking between the CS Ti and BL. The deposition and adhesion mechanisms were determined by analyzing the microstructure and the results were supported by FEA. Interface engineering of the bond layer microstructure can enable hybrid process routes to impart metal-like durability to composites for light-weighting of structures and facilitating rapid repair. Hybrid bond layers can be engineered to mitigate the disparate properties of different materials to meet the design requirements for various applications.

References: [1] A. Viscusi, R. Della Gatta, F. Delloro, I. Papa, A. S. Perna, and A. Astarita, “A novel manufacturing route for integrated 3D-printed composites and cold-sprayed metallic layer,” Mater. Manuf. Process., vol. 37, no. 5, pp. 568–581, 2022. [2] P. Feng, M. R. Rokni, and S. R. Nutt, “Depositing Aluminum onto PEKK Composites by Cold Spray,” J. Therm. Spray Technol., vol. 30, no. 1–2, pp. 385–393, 2021. [3] R. Della Gatta, A. Viscusi, A. S. Perna, A. Caraviello, and A. Astarita, “Cold spray process for the production of AlSi10Mg coatings on glass fibers reinforced polymers,” Mater. Manuf. Process., vol. 36, no. 1, pp. 106–121, 2021. [4] M. R. Rokni, P. Feng, C. A. Widener, and S. R. Nutt, “Depositing Al-Based Metallic Coatings onto Polymer Substrates by Cold Spray,” J. Therm. Spray Technol., vol. 28, no. 7, pp. 1699–1708, 2019. [5] P. Fallah, S. Rajagopalan, A. McDonald, and S. Yue, “Development of hybrid metallic coatings on carbon fiber-reinforced polymers (CFRPs) by cold spray deposition of copper-assisted copper electroplating process,” Surf. Coatings Technol., vol. 400, no. July, 2020. [6] P. Fallah, R. Chakrabarty, J. Song, A. McDonald, and S. Yue, “Effect of Metallic Interlayer Hardness on Deposition Characteristics of Cold-Sprayed Copper Particles on Carbon Fiber-Reinforced Polymers,” J. Therm. Spray Technol., vol. 31, no. 3, pp. 559–573, 2022. [7] V. Bortolussi, B. Figliuzzi, F. Willot, M. Faessel, and M. Jeandin, “Electrical Conductivity of Metal–Polymer Cold Spray Composite Coatings onto Carbon Fiber-Reinforced Polymer,” J. Therm. Spray Technol., vol. 29, no. 4, pp. 642–656, 2020. [8] G. Archambault, B. Jodoin, S. Gaydos, and M. Yandouzi, “Metallization of carbon fiber reinforced polymer composite by cold spray and lay-up molding processes,” Surf. Coatings Technol., vol. 300, pp. 78–86, 2016. [9] H. Che, S. Yue, P. Vo, and S. Yue, “Investigation of Cold Spray on Polymers by Single Particle Impact Experiments,” J. Therm. Spray Technol., vol. 28, no. 1–2, pp. 135–143, Jan. 2019. [10] J. Sun et al., “Thermal Effects in Sn Coating on a Carbon Fiber Reinforced Plastic by Cold Spraying,” J. Therm. Spray Technol., vol. 30, no. 5, pp. 1254–1261, 2021. [11] H. Che, P. Vo, and S. Yue, “Metallization of carbon fibre reinforced polymers by cold spray,” Surf. Coatings Technol., vol. 313, pp. 236–247, 2017. [12] A. C. Liberati, H. Che, P. Vo, and S. Yue, “Observation of an Indirect Deposition Effect while Cold Spraying Sn-Al Mixed Powders onto Carbon Fiber Reinforced Polymers,” J. Therm. Spray Technol., vol. 29, no. 1–2, pp. 134–146, 2020. [13] X. L. Zhou, A. F. Chen, J. C. Liu, X. K. Wu, and J. S. Zhang, “Preparation of metallic coatings on polymer matrix composites by cold spray,” Surf. Coatings Technol., vol. 206, no. 1, pp. 132–136, 2011. [14] Y. Xie, S. Yin, J. Cizek, J. Cupera, E. Guo, and R. Lupoi, “Formation mechanism and microstructure characterization of nickel-aluminum intertwining interface in cold spray,” Surf. Coatings Technol., vol. 337, no. February, pp. 447–452, 2018. [15] V. K. Champagne, D. Helfritch, P. Leyman, S. Grendahl, and B. Klotz, “Interface material mixing formed by the deposition of copper on aluminum by means of the cold spray process,” J. Therm. Spray Technol., vol. 14, no. 3, pp. 330–334, 2005. [16] R. Nikbakht, S. H. Seyedein, S. Kheirandish, H. Assadi, and B. Jodoin, “The role of deposition sequence in cold spraying of dissimilar materials,” Surf. Coatings Technol., vol. 367, no. March, pp. 75–85, 2019. [17] S. Yin et al., “Formation conditions of vortex-like intermixing interfaces in cold spray,” Mater. Des., vol. 200, p. 109444, 2021. [18] M. Hassani-Gangaraj, D. Veysset, V. K. Champagne, K. A. Nelson, and C. A. Schuh, “Adiabatic shear instability is not necessary for adhesion in cold spray,” Acta Mater., vol. 158, pp. 430–439, 2018. [19] S. Yin, X. Suo, J. Su, Z. Guo, H. Liao, and X. Wang, “Effects of substrate hardness and spray angle on the deposition behavior of cold-sprayed ti particles,” J. Therm. Spray Technol., vol. 23, no. 1–2, pp. 76–83, 2014. [20] K. Binder, J. Gottschalk, M. Kollenda, F. Gärtner, and T. Klassen, “Influence of impact angle and gas temperature on mechanical properties of titanium cold spray deposits,” J. Therm. Spray Technol., vol. 20, no. 1–2, pp. 234–242, 2011. [21] K. Loke et al., “Residual Stress Analysis of Cold Spray Coatings Sprayed at Angles Using Through-thickness Neutron Diffraction Measurement,” J. Therm. Spray Technol., vol. 30, no. 7, pp. 1810–1826, 2021. [22] D. H. L. SENG et al., “Influence of spray angle in cold spray deposition of Ti-6Al-4V coatings on Al6061-T6 substrates,” Surf. Coatings Technol., vol. 432, no. November 2021, p. 128068, 2022. [23] A. Fardan, C. C. Berndt, and R. Ahmed, “Numerical modelling of particle impact and residual stresses in cold sprayed coatings: A review,” Surf. Coatings Technol., vol. 409, p. 126835, 2021. [24] D. Thomas, “Development of Design Rules for SLM,” Thesis, 2009. [25] A. Garaigordobil, R. Ansola, E. Veguería, and I. Fernandez, “Overhang constraint for topology optimization of self-supported compliant mechanisms considering additive manufacturing,” CAD Comput. Aided Des., vol. 109, pp. 33–48, 2019. [26] A. T. Gaynor and J. K. Guest, “Topology optimization considering overhang constraints: Eliminating sacrificial support material in additive manufacturing through design,” Struct. Multidiscip. Optim., vol. 54, no. 5, pp. 1157–1172, 2016. [27] K. Zhang and G. Cheng, “Three-dimensional high resolution topology optimization considering additive manufacturing constraints,” Addit. Manuf., vol. 35, no. May, 2020. [28] Y. H. Kuo and C. C. Cheng, “Self-supporting structure design for additive manufacturing by using a logistic aggregate function,” Struct. Multidiscip. Optim., vol. 60, no. 3, pp. 1109–1121, 2019. [29] A. P. Alkhimov, V. F. Kosarev, and S. V. Klinkov, “The features of cold spray nozzle design,” J. Therm. Spray Technol., vol. 10, no. 2, pp. 375–381, 2001. [30] J. Pattison, S. Celotto, A. Khan, and W. O’Neill, “Standoff distance and bow shock phenomena in the Cold Spray process,” Surf. Coatings Technol., vol. 202, no. 8, pp. 1443–1454, 2008. [31] D. L. Gilmore, R. C. Dykhuizen, R. A. Neiser, T. J. Roemer, and M. F. Smith, “Particle velocity and deposition efficiency in the cold spray process,” J. Therm. Spray Technol., vol. 8, no. 4, pp. 576–582, 1999. [32] B. Samareh and A. Dolatabadi, “A three-dimensional analysis of the cold spray process: The effects of substrate location and shape,” J. Therm. Spray Technol., vol. 16, no. 5–6, pp. 634–642, 2007. [33] S. Yin, X. F. Wang, W. Y. Li, and B. P. Xu, “Numerical study on the effect of substrate angle on particle impact velocity and normal velocity component in cold gas dynamic spraying based on CFD,” J. Therm. Spray Technol., vol. 19, no. 6, pp. 1155–1162, 2010. [34] M. Faizan-Ur-Rab et al., “Utilization of Titanium Particle Impact Location to Validate a 3D Multicomponent Model for Cold Spray Additive Manufacturing,” J. Therm. Spray Technol., vol. 26, no. 8, pp. 1874–1887, 2017. [35] D. MacLucas, B. Skews, and H. Kleine, “Shock wave interactions within concave cavities,” Exp. Fluids, vol. 61, no. 3, 2020.

Conference: CAMX 2022

Publication Date: 2022/10/17

SKU: TP22-0000000071

Pages: 12

Price: $24.00