Abstract
In previous studies at McGill University, tin has successfully been cold sprayed onto carbon fiber reinforced polymers (CFRPs) and, with the idea of improving the coating conductivity, other metal powders (aluminum, copper and zinc) were added to tin and also sprayed. Results indicated that addition of any of the aforementioned secondary components (SCs) provided a noticeable increase in deposition efficiency (DE); it was hypothesized that a tamping mechanism might explain the improvement. In this study, aluminum and several aluminum alloys (5083, 6061, 7075) were mixed with tin powders to understand how the hardness of secondary components with similar densities may affect the deposition of tin on CFRPs. The top-surface and cross section of the coatings were examined, and DE and coating thicknesses were measured. Profilometric data were acquired on some coating top surfaces, as well as directly on some substrates after coatings peeled off. Mixing tin with other metallic powders is discussed and a refined “crack filling” mechanism related to SC hardness is explored as an improvement mechanism in the cold spraying of mixed powders on CFRPs.
Similar content being viewed by others
References
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.
S. Black, Lightning Strike Protection Strategies for Composite Aircraft, High-Perform. Compos., 2013, 21(3), p 52-61.
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. Coat. Technol., 2016, 300, p 78-86.
S. Devaraj, B. Anand, M. Gibbons, A. McDonald, and S. Chandra, Thermal Spray Deposition of Aluminum and Zinc Coatings on Thermoplastics, Surf. Coat. Technol., 2020, 399, p 126114.
C. Feng, M. Gibbons, and S. Chandra, Fabrication of Composite Heat Sinks Consisting of a Thin Metallic Skin and a Polymer Core Using Wire-Arc Spraying, J. Therm. Spray Technol., 2019, 28(5), p 974-985.
R. Wang, D. Song, W. Liu, and X. He, Effect of Arc Spraying Power on the Microstructure and Mechanical Properties of Zn-Al Coating Deposited onto Carbon Fiber Reinforced Epoxy Composites, Appl. Surf. Sci., 2010, 257(1), p 203-209.
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.
D. Zhang, P.H. Shipway, and D.G. McCartney, Cold Gas Dynamic Spraying of Aluminum: The Role of Substrate Characteristics in Deposit Formation, J. Therm. Spray Technol., 2005, 14(1), p 109-116.
A. Ganesan, M. Yamada, and M. Fukumoto, The Effect of CFRP Surface Treatment on the Splat Morphology and Coating Adhesion Strength, J. Therm. Spray Technol., 2013, 23(1-2), p 236-244.
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.
H. Che, P. Vo, and S. Yue, Metallization of Carbon Fibre Reinforced Polymers by Cold Spray, Surf. Coat. Technol., 2017, 313, p 236-247.
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, 28(7), p 1699-1708.
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.
H. Che, X. Chu, P. Vo, and S. Yue, Metallization of Various Polymers by Cold Spray, J. Therm. Spray Technol., 2017, 27(1-2), p 169-178.
A. Małachowska, M. Winnicki, Ł Konat, T. Piwowarczyk, L. Pawłowski, A. Ambroziak, and M. Stachowicz, Possibility of Spraying of Copper Coatings on Polyamide 6 with Low Pressure Cold Spray Method, Surf. Coat. Technol., 2017, 318, p 82-89.
R. Della Gatta, A. Viscusi, A. Serena Perna, A. Caraviello, and A. Astarita, Cold Spray Process for the Production of AlSi10Mg Coatings on Glass Fibers Reinforced Polymers, Mater. Manuf. Process., 2021, 36(1), p 106-121.
R. Della Gatta, A. Viscusi, A. Serena Perna, A. Caraviello, and A. Astarita, Feasibility of Steel Powder Deposition on Composites through Cold Spray, Mater. Manuf. Process., 2021, 36(3), p 281-291.
V. Gillet, E. Aubignat, S. Costil, B. Courant, C. Langlade, P. Casari, W. Knapp, and M.P. Planche, Development of Low Pressure Cold Sprayed Copper Coatings on Carbon Fiber Reinforced Polymer (CFRP), Surf. Coat. Technol., 2019, 364, p 306-316.
L.L. Koithara, R.N. Raoelison, S. Costil, and X. Xie, High Deposition Efficiency and Delamination Issues during High-Pressure Cold Spraying Metallization of PEEK using Spherical Copper Powders, Int. J. Adv. Manuf. Tech., 2020, 107(11-12), p 4427-4436.
P. Lomonaco, S. Weiller, I. Feki, A. Debray, F. Delloro, M. Jeandin, B. Favini, and C. Rossignol, Cold Spray Technology to Promote Conductivity of Short Carbon Fiber Reinforced Polyether-Ether-Ketone (PEEK), Key Eng. Mat., 2019, 813, p 459-464.
E. Irissou, J.-G. Legoux, B. Arsenault, and C. Moreau, Investigation of Al-Al2O3 Cold Spray Coating Formation and Properties, J. Therm. Spray Technol., 2007, 16(5-6), p 661-668.
H. Koivuluoto and P. Vuoristo, Effect of Powder Type and Composition on Structure and Mechanical Properties of Cu + Al2O3 Coatings Prepared by using Low-Pressure Cold Spray Process, J. Therm. Spray Technol., 2010, 19(5), p 1081-1092.
H.Y. Lee, Y.H. Yu, Y.C. Lee, Y.P. Hong, and K.H. Ko, Cold Spray of SiC and Al2O3 With Soft Metal Incorporation: A Technical Contribution, J. Therm. Spray Technol., 2004, 13(2), p 184-189.
X.-T. Luo, Y.-K. Wei, Y. Wang, and C.-J. Li, Microstructure and Mechanical Property of Ti and Ti6Al4V Prepared by an In-Situ Shot Peening Assisted Cold Spraying, Mater. Design, 2015, 85, p 527-533.
R. Fernandez and B. Jodoin, Cold Spray Aluminum-Alumina Cermet Coatings: Effect of Alumina Content, J. Therm. Spray Technol., 2018, 27(4), p 603-623.
R. Fernandez and B. Jodoin, Cold Spray Aluminum-Alumina Cermet Coatings: Effect of Alumina Morphology, J. Therm. Spray Technol., 2019, 28(4), p 737-755.
H. Che, X. Chu, P. Vo, and S. Yue, Cold Spray of Mixed Metal Powders on Carbon Fibre Reinforced Polymers, Surf. Coat. Technol., 2017, 329, p 232-243.
H. Che, A. Liberati, P. Vo, and S. Yue, Cold Spray of Mixed Sn-Zn and Sn-Al Powders on Carbon Fiber Reinforced Polymers, Mater. Sci. Forum, 2018, 941. p 1892-1897
F. Meng, D. Hu, Y. Gao, S. Yue, and J. Song, Cold-Spray Bonding Mechanisms and Deposition Efficiency Prediction for Particle/Substrate with Distinct Deformability, Mater. Des., 2016, 109, p 503-510.
A. Sova, R. Maestracci, M. Jeandin, Ph. Bertrand, and I. Smurov, Kinetics of Composite Coating Formation Process in Cold Spray: Modelling and Experimental Validation, Surf. Coat. Technol., 2017, 318, p 309-314.
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., 2020, 29, p 134-146.
C. Gomez, R. Su, A. Thompson, J. DiSciacca, S. Lawes, and R.K. Leach, Optimization of Surface Measurement for Metal Additive Manufacturing using Coherence Scanning Interferometry, Opt. Eng., 2017, 56(11), p 111714.
Mx Surface Texture Parameters, Zygo, AMETEK Inc., 2018
N.-M. Barkoula and J. Karger-Kocsis, Review Processes and Influencing Parameters of the Solid Particle Erosion of Polymers and their Composites, J. Mater. Sci., 2002, 37(18), p 3807-3820.
N. Miyazaki and N. Takeda, Solid Particle Erosion of Fiber Reinforced Plastics, J. Compos. Mater., 1993, 27(1), p 21-31.
W. Wong, P. Vo, E. Irissou, A.N. Ryabinin, J.-G. Legoux, and S. Yue, Effect of Particle Morphology and Size Distribution on Cold-Sprayed Pure Titanium Coatings, J. Therm. Spray Technol., 2013, 22(7), p 1140-1153.
Acknowledgments
The authors wish to acknowledge the financial support of the Natural Sciences and Engineering Research Council of Canada (NSERC) through the Green-SEAM strategic network and the McGill Engineering Doctoral Award (MEDA). The industrial partners, Bombardier Aerospace and Tencate (through Pratt and Whitney Canada) are gratefully acknowledged. Mr. Kévin Bricault from National Research Council Canada, Boucherville, is acknowledged for his contribution to the cold spray experiments.
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Liberati, A.C., Che, H., Vo, P. et al. Influence of Secondary Component Hardness When Cold Spraying Mixed Metal Powders on Carbon Fiber Reinforced Polymers. J Therm Spray Tech 30, 1239–1253 (2021). https://doi.org/10.1007/s11666-021-01197-9
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11666-021-01197-9