Abstract
Single component tin coatings have been successfully cold-sprayed onto carbon fiber reinforced polymers. Coatings with mixed metal powders have also been sprayed to improve conductivity for lightning strike protection purposes. Test results indicate a noticeable improvement in deposition efficiency with the addition of a secondary metallic powder. This study examines the effect of aluminum powder additions in tin coatings. Following cold spraying of various Sn-Al mixtures over a wide range of gas pressures, unusual coating morphologies were observed. The study of these morphologies reveals two distinct deposition phases depending on spray pressure. The presence of submicron particles also supports the occurrence of a powder melting phenomenon during the spraying process.
