Skip to main content
SpringerLink
Log in

Depositing Aluminum onto PEKK Composites by Cold Spray

  • Peer Reviewed
  • Published:
Journal of Thermal Spray Technology Aims and scope Submit manuscript

Abstract

High-pressure cold spray (HP-CS) was used to deposit aluminum onto polyetherketoneketone (PEKK) composite substrates. Aluminum powders were sprayed using N2 and He carrier gas and a bond layer (BL) of commercial-purity Al (CP Al). Dense 7075 and CP Al deposits were achieved via combinations of BL-N2, 7075/BL-N2, and 7075/BL-He. Cold spray using 7075 Al particles or using He carrier gas yielded thinner deposits because of self-erosion and bond layer erosion. Substrate roughening was more severe when using He gas and generated more polymer debris at the deposit–substrate interface, yielding lower adhesive strength values between the deposit and the composite substrates. Adhesive strength depended on the bonding of initial particle layers that fused with the substrate.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7

Similar content being viewed by others

References

  1. A. Ganesan, J. Affi, M. Yamada, and M. Fukumoto, Bonding Behavior Studies of Cold Sprayed Copper Coating on the PVC Polymer Substrate, Surf. Coat. Technol., 2012, 207, p 262-269.

    Article  CAS  Google Scholar 

  2. A.S. Perna, A. Viscusi, A. Astarita, L. Boccarusso, L. Carrino, M. Durante, and R. Sansone, Manufacturing of a Metal Matrix Composite Coating on a Polymer Matrix Composite Through Cold Gas Dynamic Spray Technique, J. Mater. Eng. Perform., 2019, https://doi.org/10.1007/s11665-019-03914-6

    Article  Google Scholar 

  3. H. Che, M. Gagné, P.S.M. Rajesh, J.E. Klemberg-Sapieha, F. Sirois, D. Therriault, and S. Yue, Metallization of Carbon Fiber Reinforced Polymers for Lightning Strike Protection, J. Mater. Eng. Perform., 2018, 27(10), p 5205-5211.

    Article  CAS  Google Scholar 

  4. A. Viscusi, A. Astarita, R. Della Gatta, F. Rubino, A Perspective Review on the Bonding Mechanisms in Cold Gas Dynamic Spray, Surf. Eng., 2019, 0844, p 743–771.

    Article  Google Scholar 

  5. B. Fotovvati, N. Namdari, and A. Dehghanghadikolaei, On Coating Techniques for Surface Protection: A Review, J. Manuf. Mater. Process., 2019, 3(1), p 28.

    CAS  Google Scholar 

  6. Y.J. Yim, K.Y. Rhee, and S.J. Park, Influence of Electroless Nickel-Plating on Fracture Toughness of Pitch-Based Carbon Fibre Reinforced Composites, Compos. Part B Eng., 2015, 76, p 286-291. https://doi.org/10.1016/j.compositesb.2015.01.052

    Article  CAS  Google Scholar 

  7. M. Ivosevic, R. Knight, S.R. Kalidindi, G.R. Palmese, and J.K. Sutter, Adhesive/Cohesive Properties of Thermally Sprayed Functionally Graded Coatings for Polymer Matrix Composites, J. Therm. Spray Technol., 2005, 14(1), p 45-51.

    Article  Google Scholar 

  8. R. Gonzalez, H. Ashrafizadeh, A. Lopera, P. Mertiny, and A. McDonald, A Review of Thermal Spray Metallization of Polymer-Based Structures, J. Therm. Spray Technol., 2016, 25(5), p 897-919.

    Article  CAS  Google Scholar 

  9. J. Villafuerte, Modern Cold Spray: Materials, Process, and Applications (Springer, Berlin, 2015). https://doi.org/10.1007/978-3-319-16772-5.

    Book  Google Scholar 

  10. P. Cavaliere, Cold-Spray Coatings: Recent Trends and Future Perspectives (Springer, Berlin, 2015). https://doi.org/10.1007/978-3-319-67183-3.

    Book  Google Scholar 

  11. 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. Coat. Technol., 2011, 206(1), p 132-136.

    Article  CAS  Google Scholar 

  12. F. Robitaille, M. Yandouzi, S. Hind, and B. Jodoin, Metallic Coating of Aerospace Carbon/Epoxy Composites by the Pulsed Gas Dynamic Spraying Process, Surf. Coat. Technol., 2009, 203(19), p 2954-2960.

    Article  CAS  Google Scholar 

  13. R. Lupoi and W. O’Neill, Deposition of Metallic Coatings on Polymer Surfaces Using Cold Spray, Surf. Coat. Technol., 2010, 205(7), p 2167-2173.

    Article  CAS  Google Scholar 

  14. V. Champagne and D. Helfritch, The Unique Abilities of Cold Spray Deposition, Int. Mater. Rev., 2016, 61(7), p 437-455.

    Article  CAS  Google Scholar 

  15. A. Ganesan, M. Yamada, and M. Fukumoto, Cold Spray Coating Deposition Mechanism on the Thermoplastic and Thermosetting Polymer Substrates, J. Therm. Spray Technol., 2013, 22(8), p 1275-1282.

    Article  CAS  Google Scholar 

  16. P.C. King, A.J. Poole, S. Horne, R. de Nys, S. Gulizia, and M.Z. Jahedi, Embedment of Copper Particles into Polymers by Cold Spray, Surf. Coat. Technol., 2013, 216, p 60-67.

    Article  CAS  Google Scholar 

  17. C. Stenson, K.A. McDonnell, S. Yin, B. Aldwell, M. Meyer, D.P. Dowling, and R. Lupoi, Cold Spray Deposition to Prevent Fouling of Polymer Surfaces, Surf. Eng., 2018, 34(3), p 193-204.

    Article  CAS  Google Scholar 

  18. H. Che, P. Vo, and S. Yue, Metallization of Various Polymers by Cold Spray, J. Therm. Spray Technol., 2018, 27(1–2), p 169-178.

    Article  CAS  Google Scholar 

  19. 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., 2019, https://doi.org/10.1007/s11666-019-00911-y

    Article  Google Scholar 

  20. H. Che, P. Vo, and S. Yue, Investigation of Cold Spray on Polymers by Single Particle Impact Experiments, J. Therm. Spray Technol., 2019, 28(1–2), p 135-143. https://doi.org/10.1007/s11666-018-0801-4

    Article  Google Scholar 

  21. M. Gardon, A. Latorre, M. Torrell, S. Dosta, J. Fernández, and J.M. Guilemany, Cold Gas Spray Titanium Coatings onto a Biocompatible Polymer, Mater. Lett., 2013, 106, p 97-99. https://doi.org/10.1016/j.matlet.2013.04.115

    Article  CAS  Google Scholar 

  22. 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., 2020, 29(4), p 642-656.

    Article  CAS  Google Scholar 

  23. A. Małachowska, M. Winnicki, M. Stachowicz, and M. Korzeniowski, Metallisation of Polycarbonates Using a Low Pressure Cold Spray Method, Surf. Eng., 2018, 34(3), p 251-258.

    Article  Google Scholar 

  24. A. Astarita, L. Boccarusso, M. Durante, A. Viscusi, R. Sansone, and L. Carrino, Study of the Production of a Metallic Coating on Natural Fiber Composite Through the Cold Spray Technique, J. Mater. Eng. Perform., 2018, 27(2), p 739-750.

    Article  CAS  Google Scholar 

  25. I. Burlacov, J. Jirkovský, L. Kavan, R. Ballhorn, and R.B. Heimann, Cold Gas Dynamic Spraying (CGDS) of TiO2 (Anatase) Powders onto Poly(Sulfone) Substrates: Microstructural Characterisation and Photocatalytic Efficiency, J. Photochem. Photobiol. A Chem., 2007, 187(2–3), p 285-292.

    Article  CAS  Google Scholar 

  26. J. Affi, H. Okazaki, M. Yamada, and M. Fukumoto, Fabrication of Aluminum Coating onto CFRP Substrate by Cold Spray, Mater. Trans., 2011, 52(9), p 1759-1763.

    Article  CAS  Google Scholar 

  27. Granta Design, “CES EduPack,” Granta Design, 2019.

  28. ASTM D4541-17, Standard Test Method for Pull-Off Strength of Coatings Using Portable Adhesion, ASTM Int, 2017.

  29. M. Grujicic, C.L. Zhao, C. Tong, W.S. DeRosset, and D. Helfritch, Analysis of the Impact Velocity of Powder Particles in the Cold-Gas Dynamic-Spray Process, Mater. Sci. Eng. A, 2004, 368(1–2), p 222-230.

    Article  Google Scholar 

  30. N. Cinca, M. Barbosa, S. Dosta, and J.M. Guilemany, Study of Ti Deposition onto Al Alloy by Cold Gas Spraying, Surf. Coat. Technol., 2010, 205(4), p 1096-1102.

    Article  CAS  Google Scholar 

  31. S. Adachi and N. Ueda, Effect of Cold-Spray Conditions Using a Nitrogen Propellant Gas on AISI 316L Stainless Steel-Coating Microstructures, Coatings, 2017, 7(7), p 3-11.

    Google Scholar 

  32. C. Chen, X. Xie, Y. Xie, X. Yan, C. Huang, S. Deng, Z. Ren, and H. Liao, Metallization of Polyether Ether Ketone (PEEK) by Copper Coating via Cold Spray, Surf. Coat. Technol., 2018, 342(1), p 209-219. https://doi.org/10.1016/j.surfcoat.2018.02.087

    Article  CAS  Google Scholar 

  33. Y. Xiong, W. Zhuang, and M. Zhang, Effect of the Thickness of Cold Sprayed Aluminium Alloy Coating on the Adhesive Bond Strength with an Aluminium Alloy Substrate, Surf. Coat. Technol., 2015, 270, p 259-265. https://doi.org/10.1016/j.surfcoat.2015.02.048

    Article  CAS  Google Scholar 

  34. Y. Watanabe, C. Yoshida, K. Atsumi, M. Yamada, and M. Fukumoto, Influence of Substrate Temperature on Adhesion Strength of Cold-Sprayed Coatings, J. Therm. Spray Technol., 2014, 24(1–2), p 86-91.

    Google Scholar 

  35. E. Cortés, F. Sánchez, A. O’Carroll, B. Madramany, M. Hardiman, and T.M. Young, On the Material Characterisation of Wind Turbine Blade Coatings: The Effect of Interphase Coating-Laminate Adhesion on Rain Erosion Performance, Materials (Basel), 2017, 10(10), p 1146.

    Article  Google Scholar 

  36. A.W. Momber, P. Plagemann, and V. Stenzel, The Adhesion of Corrosion Protection Coating Systems for Offshore Wind Power Constructions after Three Years under Offshore Exposure, Int. J. Adhes. Adhes., 2016, 65, p 96-101. https://doi.org/10.1016/j.ijadhadh.2015.11.011

    Article  CAS  Google Scholar 

Download references

Acknowledgments

The authors acknowledge financial support from Concepts to Systems, Inc. (Dr. Shiv Joshi, PI) through an SBIR contract supported by the US Army (W9113M-18-C-0014). The authors also thank Dr. Marius Ellingsen of VRC Metal Systems for cold-spraying samples and fulfilling custom requests in a timely fashion.

Author information

Author notes

  1. M. R. Rokni

    Present address: Senior Aerospace SSP, Los Angeles, CA, USA

Authors and Affiliations

  1. Department of Chemical Engineering and Materials Science, M.C. Gill Composites Center, University of Southern California, Los Angeles, CA, USA

    P. Feng, M. R. Rokni & S. R. Nutt

Authors
  1. P. Feng
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. M. R. Rokni
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. S. R. Nutt
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to P. Feng.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Feng, P., Rokni, M.R. & Nutt, S.R. Depositing Aluminum onto PEKK Composites by Cold Spray. J Therm Spray Tech 30, 385–393 (2021). https://doi.org/10.1007/s11666-020-01125-3

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11666-020-01125-3

Keywords

Search

Navigation