ABSTRACT

Polymer matrix composites (PMCs) are the most used in aerospace fields due to their special mechanical properties coupled with reduced weight. Metallic structures can be manufactured on the surface of PMCs producing hybrid constructions with intriguing characteristics. The cold spray technology (CS) seems to be the best solution for the manufacturing of metallic coatings on polymer-based substrates. However, the last researches on PMCs metallization through CS were carried out without taking into account a proper manufacturing of the substrates. Therefore, the customized manufacturing of PMCs used as substrates for CS deposition represents a crucial aspect to be considered, the target surface should be designed and manufactured to fit better the CS requirements. In this scenario, the Fused Filament Fabrication method (FFF) is the best solution for tailored composites manufacturing. Therefore, this work aims to develop a novel manufacturing route to produce innovative composite structures by using the FFF technology for the 3D-printed polymer-based substrate and the cold spray technology for the 3D-printed metal deposition. The novelty is that, for the first time, the polymer-based substrates will be designed and manufactured “ad hoc” for the cold spray metallization by using the rapid prototyping 3D-printing process successfully integrated with CS technology.

摘要

聚合物基复合材料 (PMC) 因其特殊的机械性能和较轻的重量而在航空航天领域中使用最多。金属结构可以在 PMC 的表面上制造，从而产生具有有趣特性的混合结构。冷喷涂技术 (CS) 似乎是在聚合物基基材上制造金属涂层的最佳解决方案。然而，最近对通过 CS 进行 PMC 金属化的研究没有考虑到基板的正确制造。因此，用作 CS 沉积基板的 PMC 的定制制造是一个需要考虑的关键方面，应设计和制造目标表面以更好地满足 CS 要求。在这种情况下，熔丝制造方法 (FFF) 是定制复合材料制造的最佳解决方案。因此，这项工作旨在开发一种新的制造路线，通过将 FFF 技术用于 3D 打印聚合物基基板和冷喷涂技术用于 3D 打印金属沉积来生产创新的复合结构。新颖之处在于，首次使用与 CS 技术成功集成的快速原型 3D 打印工艺，为冷喷涂金属化设计和制造聚合物基基板。这项工作旨在开发一种新的制造路线，通过将 FFF 技术用于 3D 打印的聚合物基基板和冷喷涂技术用于 3D 打印的金属沉积来生产创新的复合结构。新颖之处在于，首次使用与 CS 技术成功集成的快速原型 3D 打印工艺，为冷喷涂金属化设计和制造聚合物基基板。这项工作旨在开发一种新的制造路线，通过将 FFF 技术用于 3D 打印的聚合物基基板和冷喷涂技术用于 3D 打印的金属沉积来生产创新的复合结构。新颖之处在于，首次使用与 CS 技术成功集成的快速原型 3D 打印工艺，为冷喷涂金属化设计和制造聚合物基基板。