The Effect of CFRP Surface Treatment on the Splat Morphology and Coating Adhesion Strength

Cold spraying is a promising candidate for the metallization of carbon fiber reinforced polymer (CFRP) composites, but it requires the use of a protective interlayer deposited by either flame or plasma spray. This study evaluates the effect of different surface treatments on interlayer adhesion strength. CFRP samples were treated mechanically, chemically, and thermally and then a copper layer was deposited by atmospheric plasma spraying. Adhesion strength was measured by pullout testing and the results are compared with surface roughness measurements, SEM fracture surface images, FIB bisections of single Cu splats, and XPS analysis of the chemical affinity between the polymer and copper.