Abstract
Metals were deposited using wire-arc spray-on components made by 3D printing with polyvinyl alcohol (PVA), a water-soluble polymer. The polymer was then dissolved, leaving a metal layer whose surface topography was negative to that of the polymer. This is a rapid and low-cost alternative to 3D printing directly using metal, but to succeed it is essential for the sprayed metal to adhere to the polymer substrate. Tests were done in which aluminum and copper were sprayed using a twin-wire arc spray system onto 3D printed coupons, 50 × 50 mm in size, made from PVA, polylactic acid (PLA), and PLA mixed with metal (aluminum, copper) or carbon fiber. Adhesion depended on substrate roughness (minimum 1-2 µm) substrate temperature (above the glass transition temperature but below the melting temperature of the polymer) and minimizing residual stresses due to mismatch of the thermal expansion coefficients of metal and polymer. It was shown that surface features could be made on metal components using this technique. Plates with internal flow passages were made by placing 3D printed PVA parts in channels machined in the plates, spraying metal over the polymer, and then dissolving the polymer.
Similar content being viewed by others
Abbreviations
- Al:
-
Aluminum
- Cu:
-
Copper
- PLA:
-
Polylactic acid
- PVA:
-
Polyvinyl alcohol
- SEM:
-
Scanning electron microscope
- \({E}_{c}\) :
-
Young's modulus (N/mm2)
- \(L\) :
-
Length of the component (m)
- \(\Delta {L}_{s}\) :
-
Change in substrates length (m)
- \({t}_{c}\) :
-
Thickness of the coating (m)
- \({t}_{s}\) :
-
Thickness of the substrate (m)
- \({T}_{g}\) :
-
Glass transition temperature (°C)
- \({T}_{m}\) :
-
Melting temperature (°C)
- \(R\) :
-
Radius of curvature (m)
- \({R}_{a}\) :
-
Surface roughness (μm)
- \(\Delta T\) :
-
Temperature decrease (°C)
- \(V\) :
-
Voltage (V)
- \({\alpha }_{c}\) :
-
Coefficient of thermal expansion of coating material (°C−1)
- \({\alpha }_{s}\) :
-
Coefficient of thermal expansion of substrate material (°C−1)
- \(\delta\) :
-
Deflection in the component (m)
- \(\varepsilon\) :
-
Strain in the component
- \({\nu }_{c}\) :
-
Poisson’s ratio of the coating material
- \({\nu }_{s}\) :
-
Poisson’s ratio of the substrate material
- \({\sigma }_{A}\) :
-
Adhesive strength (MPa)
- \({\sigma }_{c}\) :
-
Stress in the coating (N/mm2)
- \(\kappa\) :
-
Curvature (m−1)
- c:
-
Coating
- s:
-
Substrate
References
J. Villafuerte, Considering Cold Spray for Additive Manufacturing, Adv. Mater. Process., 2014, 172(5), p 50-52.
N. Shahrubudin, T.C. Lee and R. Ramlan, An Overview on 3D Printing Technology: Technological, Materials, and Applications, Procedia Manuf., 2019, 35, p 1286-1296.
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.
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., 2016, 300, p 78-86.
H. Che, P. Vo and S. Yue, Metallization of Carbon Fibre Reinforced Polymers by Cold Spray, Surf. Coatings Technol., 2017, 313, p 236-247.
H. Che, A.C. Liberati, X. Chu, M. Chen, A. Nobari, P. Vo and S. Yue, Metallization of Polymers by Cold Spraying with Low Melting Point Powders, Surf. Coatings Technol., 2021, 418, p 127229.
A. Rezzoug, S. Abdi, A. Kaci and M. Yandouzi, Thermal Spray Metallisation of Carbon Fibre Reinforced Polymer Composites: Effect of Top Surface Modification on Coating Adhesion and Mechanical Properties, Surf. Coatings Technol., 2018, 333, p 13-23.
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. Coatings Technol., 2018, 342, p 209-219.
R. Melentiev, N. Yu and G. Lubineau, Polymer Metallization via Cold Spray Additive Manufacturing: A Review of Process Control, Coating Qualities, and Prospective Applications, Addit. Manuf., 2021, 48(PB), p 102459.
R. Gonzalez, A. McDonald and P. Mertiny, Effect of Flame-Sprayed Al-12Si Coatings on the Failure Behaviour of Pressurized Fibre-Reinforced Composite Tubes, Polym. Test, 2013, 32(8), p 1522-1528.
A. Lopera-Valle and A. McDonald, Flame-Sprayed Coatings as de-Icing Elements for Fiber-Reinforced Polymer Composite Structures: Modeling and Experimentation, Int. J. Heat Mass Transf., 2016, 97, p 56-65.
S.T. Dehaghani, A. Dolatabadi and A. McDonald, Thermally Sprayed Metal Matrix Composite Coatings as Heating Systems, Appl. Therm. Eng., 2021, 196, p 117321.
S. Nigam, S.S. Mahapatra and S.K. Patel, Study of Various Aspects of Copper Coating on ABS Plastic by Electric Arc Spraying, Mater. Today Proc., 2018, 5(2), p 8446-8453.
S. Devaraj, B. Anand, M. Gibbons, A. McDonald and S. Chandra, Thermal Spray Deposition of Aluminum and Zinc Coatings on Thermoplastics, Surf. Coatings 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.
S. Devaraj, A. McDonald and S. Chandra, Metallization of Porous Polyethylene Using a Wire-Arc Spray Process for Heat Transfer Applications, J. Therm. Spray Technol., 2021, 30(1-2), p 145-156.
F. Cverna, Therm. Prop. Met., ASM International, 2002.
G. Wypych, Handbook of Polymers, Elsevier, 2016.
“Standard Test Method for Pull-Off Strength of Coatings Using Portable Adhesion Testers”, ASTM D4541–17, ASTM International, West Conshohocken, PA, 2017.
J. Andrade, C. González-Martínez and A. Chiralt, The incorporation of carvacrol into poly (vinyl alcohol) films encapsulated in lecithin liposomes, Polymers, 2020, 12(2), p 497.
C.A. Klein and R.P. Miller, Strains and Stresses in Multilayered Elastic Structures: The Case of Chemically Vapor-Deposited ZnS/ZnSe Laminates, J. Appl. Phys., 2000, 87, p 2265-2272.
C.A. Klein, How accurate are Stoney’s equation and recent modifications, J. Appl. Phys., 2000, 88, p 5487-5489.
Acknowledgments
The authors would like to acknowledge the financial support for this work from Natural Science and Engineering Research Council Green Surface Engineering for Advanced Manufacturing (Green-SEAM) Strategic Network.
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Conflict of interest
The authors declare that they have no conflict of interest regarding the publication of this original research article.
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Ramaraju, R.V., Chandra, S. Additive Manufacturing of Metal Components by Thermal Spray Deposition on 3D-Printed Polymer Parts. J Therm Spray Tech 31, 2409–2421 (2022). https://doi.org/10.1007/s11666-022-01450-9
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11666-022-01450-9