This research proposes an experimental methodology towards visually observing high strain rate polymer deformation characteristics at scales relevant to cold spray particle impacts. Macro-scale (~ 3 mm) polymer impact testing via a light gas gun has shown evidence of cold spray indicative features at certain (material, particle/substrate temperature, velocity, etc.) conditions.

Polymers have proven to be challenging to cold spray, particularly with high efficiency and quality when using inexpensive nitrogen (N 2 ) and air propellants. Helium (He) when used as a process propellant can improve spray deposit properties but is often undesirable due to its limited availability and high cost. In this study, additives of multiple particle sizes and materials were mixed with polymer powder in an effort to improve the performance of polymer sprays using mainly N 2 as a process propellant. The effects of additives on deposit microstructure were investigated by precise ion-beam polishing of deposit cross sections and subsequent electron microscope imaging. Additional metrics including the density and post - spray composition of deposits were investigated to quantify the peening effect and the amount of embedded additive. Additives, regardless of size, were observed to embed in the spray deposits. Additionally, hard-phase additives demonstrated nozzle-cleaning properties that continually remove polymer fouling on the nozzle walls. Inversely, sprays with polymer powder and no additives tended to clog the nozzle throat and diverging section as a result of continual fouling.

With an increasing demand for lower fuel consumption of different means of transportation, the demand for lightweight construction materials is rising. In this frame, usually metallic parts can be replaced by components consisting of fiberreinforced plastics. On the other hand, the components lose their electromagnetic field (EMF) shielding properties, which are required for many applications such as housings for electrical components. This issue can be solved by applying electrically conductive foils or meshes, often by a manual process that increases the time of production and process. In this publication, the application and parameter influence of thermally sprayed electrically conductive coatings for EMFshielding applications is discussed. Laser structuring is used as a novel surface preparation process, for the subsequent thermal spray process. The influence of the used laser-parameters is discussed accordingly. The coatings are applied by the wire-arc spray with Zinc feedstock as well as the atmospheric plasma spray (APS) process with Copper feedstock. It was found that coating properties such as adhesion strength, EMF-shield strength as well as electrical properties are provided by the proposed technology.

Fluorinated polymer coatings are potential candidates for ice protection systems. The current work aims to develop such coatings using cold spray as a production method. A computational approach is used to design a new cold spray nozzle for the efficient deposition of adhesive perfluoroalkoxy alkane. The icephobicity of as-sprayed coatings are evaluated using three-fold characterization: surface’s wetting behavior, time-lapse study of water droplets freezing, and ice adhesion at both macro and microscopic levels. While the as-sprayed coatings exhibited sought superhydrophobic properties, their behavior changed when exposed to frost formation resulting in degraded wetting behaviors and much larger ice adhesion strength. This demonstrates the importance of frost formation when studying icephobic coatings.

The feasibility of processing various polymers by cold spray has been exemplified by depositions with low porosity and properties comparable to the bulk material. However, cold sprayed polymers are generally deposited with low deposition efficiency compared to more extensively studied metal sprays. Low efficiencies in polymer sprays are attributed to characteristic differences in material properties between metals and polymers. Notably, the thermophysical properties of polymers limit heat transfer and promote intra-particle thermal gradients that develop during cold spray processing. These properties (e.g., thermal conductivity, heat capacity, density) and low deposition efficiencies demand alterations to the cold spray process equipment outside typical metal powder spray conditions. Herein, a modified powder feed tube is used to pre-heat powder to temperatures (~84 °C) below the powder melting point, or cool it (~-55 °C) below room temperature before contacting the high velocity carrier gas in the nozzle of a CSM 108 cold spray system. Numerical simulation demonstrated that pre-heating/cooling the powder feedstock is a viable means of adjusting particle temperature upon impact with the substrate; however, this technique has generally not been deliberately utilized in the cold spray of polymers. In the present work, no significant increase in deposition efficiency (~65% for all sprays) was found by increasing the pre-heat temperature. However, pre-heated particles had a mechanical strength 28% higher than particles injected at room temperature and -55 °C. Despite this, scanning electron microscope images indicated no notable differences between the deposit microstructures. Future works are planned to study the effect of pre-heat at higher particle impact velocities and degrees of pre-heat to improve powder consolidation.

Miniaturization and performance improvements of electronic devices in recent decades have significantly increased heat dissipation rates. To overcome this, researchers have developed heat sinks with miniature fluid channels to maintain small device footprints with increased heat transfer performance. These channels are often fabricated using either subtractive fabrication methods, such as etching or micro-milling, or additive methods such as direct metal laser sintering (DMLS). These methods are limited by their long processing times, low geometric accuracy, or high cost. To overcome these limitations, a novel additive manufacturing method is developed using twin wire-arc spray. Wire-arc spray was used to build complex aluminum structures with length scales varying from 0.5 mm to 74 mm. Surface structures were built on a metal plate by spraying aluminum through a 3D printed polymer mask. Internal flow passages were made by filling surface channels with a water-soluble polyvinyl alcohol (PVA) paste that was allowed to harden, spraying metal over it, and then dissolving the PVA. The influence of wire-arc spray process parameters, such as standoff distance and scanning speed, on coating solid PVA with aluminum, were also investigated.

The development of efficient ice mitigation systems for surfaces exposed to atmospheric ice has been in progress for decades. The need for passive anti-icing systems is essential as current ice mitigation systems require a substantial amount of energy and their implementation involves complex manufacturing considerations. Fluorinated polymer coatings are among the candidates for passive anti-icing systems. While many processes have been investigated to produce them, these methods can be costly, time consuming and can cause thermal damage to the substrate. The current work aims to explore a green and cheap alternative approach by using cold spray. Furthermore, the cold spray process offers advantages such as being a portable easy to perform solid-state coating process for eventual repairs. This work uses computational and experimental approaches to design and test a new dedicated nozzle for the efficient deposition of adhesive perfluoroalkoxy alkane. Computational results reveal that for the same operating conditions, the use of the new nozzle design increases particle impact temperature, improving the deposition of the feedstock material, as confirmed experimentally. The wetting behaviour, ice nucleation time and ice adhesion strength were compared for 6 different surface types, including bare aluminum, various polymer materials and the cold spray perfluoroalkoxy alkane coating on aluminium substrate. Results indicate that the as-sprayed coating performs as both a superhydrophobic and icephobic surface.

Metals were deposited on components made by 3-D printing with polyvinyl alcohol (PVA), a water-soluble polymer. The polymer was then dissolved, leaving a metal layer whose surface topography was the negative of 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 mm x 50 mm in size, made from polylactic acid (PLA), PLA mixed with metal (aluminum, copper) or carbon fiber, and PVA. Adhesion depended on substrate roughness (minimum 1-2 μm) and substrate temperature (above the glass transition temperature but below the melting temperature of the polymer). It was shown that surface features could be made with high resolution on metal components using this technique.

The cold spray process is sensitive to variations in feedstock and requires consistent powder properties, particularly flowability, to produce uniform structures. Poor powder flow causes a cascade of effects arising from erratic feeding including deposits with void spaces and inconsistent geometries. These issues result in deposits which are not suitable for testing and prevent sample replication, hindering experimental evaluation of deposits. Powder flowability is largely affected by the material preconditioning and storage conditions; with flowability directly affecting the deposit properties of deposition efficiency (DE), porosity, and surface finish. In this study, the flowability and deposit quality of a fluoropolymer-based powder was evaluated with changing pretreatment conditions. Powder flowability was analyzed by mass flowrate (g/s), the Carr angle of repose, and the Hausner ratio. Flowability was evaluated for powders as received, after sieving (45-100 μm), with drying at elevated temperature (80 °C), with inert gas vacuum purging, and after 72 hrs. of exposure to high relative humidity (95% RH). Powders exposed to humid conditions were also dried under inert gas vacuum purging to determine the effectiveness of the process as a reconditioning method. Preconditioned powders with the highest flowability according to these tests were sealed in metal containers, stored under 95% RH for one week, and reevaluated to determine the ability of this preconditioning and storage method to protect materials from exposure to undesirable conditions. Next, the effect of preconditioning on cold spray deposit quality was evaluated for the fluoropolymer-based powder with the best and worst flowability. The choice of spray conditions was informed by simulation of particle velocity and temperature distribution at impact using one-dimensional compressible flow modeling, couple with thermal analysis of the powder. The DE was determined gravimetrically, surface roughness was evaluated using a profilometer, and microstructure was evaluated using a scanning electron microscope (SEM). The ability to manipulate powder flowability through simple preconditioning methods and quickly evaluate the properties of the feedstock before use in the manufacturing process, coupled with straightforward and rapid evaluation the resultant deposit; will save time and money, and accelerate research efforts, compared to evaluating powder suitability by trial and error.

Abradable seal coatings are widely employed in the gas turbine of aero-engine, which not only strength enough to resist the impact of external particles and airflow, but also excellent wear resistance. In the current study, we concentrate on APS sprayed Aluminum Bronze Polyester abradable coating that can be used in turbo engines both for seals and clearance control. A composite thermal spray powder, substantially in the form of clad particles each of which has coarse polyester powders and sub-particles of Cu-Al alloy powders, was prepared using mechanically clad process. Abradable seal coating was prepared by atmospheric plasma spraying. The microstructure, hardness, bonding strength, thermal shock resistance and corrosion resistance of coatings were researched. Properties of the coating were able to meet the application requirements. The coating microstructures and phase compositions were evaluated via SEM. The corrosion mechanisms of the coating were compared by analyzing the cross-sectional and top surface microstructures of the as-sprayed and eroded coatings.

In suspension plasma spraying (SPS); the use of water based suspensions provides a cheaper; safer and more environmentally friendly alternative to organic liquids. However; due to the physical properties of water; producing a water based SPS coating with desirable microstructure has so far been elusive. In this study; the effects of pH and dispersant on the rheology and stability of YSZ water based suspensions were investigated. PEI; PBTCA and α-Terpineol were used as dispersant polymers. The stabilized suspensions were deposited by Axial III plasma spray system and the relationship between suspension parameters and the atomized droplet size and the final coating microstructure was studied. The results showed that a combination of Terpineol dispersant with pH adjustment to 2.5; could lead to a SPS coating with columnar microstructure having 17.4 vol.% porosity.

Masking solutions for parts needing special treatments such as shot peening, grit blasting or thermal spray are now commonly used in industrial processes for the aerospace, industrial gas turbine, and medical industries. The ever-evolving special treatment methods require adapting the masking solutions so they retain their efficiency and quality level. This paper will describe the choices made in combining materials, geometry and surface finish of the masks to provide the necessary compliance with the thermal spraying processes or other special treatment requirements. We will demonstrate that successful masking designs are often the result of close collaboration between the operator’s engineering team and the masking solutions provider in order to comply with what is always a bespoke process. Innovations in materials and additive manufacturing enable the process towards tailored solutions which enable these industries to increase their productivity and level of manufacturing quality.

Biofouling has been persisting as a worldwide problem due to the difficulties in finding efficient environment-friendly antifouling coatings for long-term applications. Developing novel coatings with desired antifouling properties has been one of the research goals for surface coating community. Recently hydrogel coating was proposed to serve as antifouling layer, for it offers the advantages of the ease of incorporating green biocides, and resisting attachment of microorganisms by its soft surface. Yet poor adhesion of the hydrogel on steel surfaces is a big concern. In this study, porous matrix aluminum coatings were fabricated by cored wire arc spray, and the sizes of the pores in the aluminum (Al) coatings were controlled by altering the size of the cored powder of sodium chloride. Silicone hydrogel was further deposited on the porous coating. The hydrogel penetrated into the open pores of the porous Al coatings, and the porous Al structure significantly enhanced the adhesion of the hydrogel. In addition, hydrogel coating exhibited very encouraging antifouling properties.

Fluoropolymer and other polymer materials are extremely difficult to coat using solid-state deposition techniques such as cold spraying. In this study, fluoroethylene propylene (FEP) is cold sprayed onto a metallic substrate in order to investigate the effect of powder size, gas temperature and pressure, and substrate surface treatments. A powder modification technique that uses fumed nanoceramic particles as an additive to the feedstock is evaluated as well. The results show that the deposition efficiency of FEP is affected by particle size, gas temperature, and traverse speed as well as the added nanoceramic which, in this case, is either silica or alumina. It is also shown that the hydrophobic properties of the fluoropolymer are retained in the coatings and that adhesion between the coating and substrate plays a critical role.

In this study, icephobic polymer coatings were produced by flame spraying using different process parameters. Process optimization for low-density polyethylene (LDPE) coatings was achieved through design of experiments. The most icephobic coating was produced at a traverse speed of 900 mm/sec and a spraying distance of 250 mm. Although surface roughness affected ice adhesion, thermal effects proved to be the main factor influencing the performance of the coating. The higher the processing temperature, the smoother the surface and the greater the polymer degradation. It is also shown that coating degradation can be caused during post heating steps with similar consequences in the ice-shedding performance of the LDPE coatings.

Tin coatings have been successfully applied to polymeric substrates by means of cold spraying. In this work, three low melting point powders, including Sn, Sn-Zn, and Sn-Bi, are cold sprayed onto various polymeric substrates and different combinations of gas temperature and pressure are assessed. Based on the results, the effect of melting points on the cold sprayability of feedstock powders is discussed.

In this study, copper coatings are deposited on polyacetal substrates by low-power microwave plasma spraying and the coating formation mechanism is investigated. In the initial formation of the coating, molten copper particles are embedded on the substrate, creating conditions for excellent bonding as confirmed by adhesion strength measurements exceeding 40 MPa. The study also shows that adding hydrogen to the argon working gas improves oxide reduction, resulting in copper coatings with volume resistivity as low as 0.049 µΩm.

Common issues such as ice formation on wind turbine blades and lightning strikes on airplanes can be mitigated by metallizing polymers and composites used on the outer surface of the component. Cold gas dynamic spray is a novel process that has the potential to be used for metallization of polymer and composite surfaces to produce electrically and/or thermally conductive components. In this study, mixed Cu-Zn and Al-Zn feedstock powders were deposited onto polypropylene and nylon-6 substrates to investigate the viability of metallizing nonmetallic surfaces using a commercially available low-pressure cold spray process. The behavior of the individual metallic particles upon impact on the polymers and the deformation of the substrate were characterized by coating the two feedstock powders onto a nylon-6 substrate over a wide temperature range. The Cu-Zn coating was deposited in thicknesses up to 1 mm onto the nylon-6 substrate using optimized parameters. To understand the deposition of the metallic powder onto the polymers, the process was modeled using computational fluid dynamics methods. The correlation of the gas and particle modeling with examination of the coating microstructure highlighted the major importance of the particle velocity during cold spray deposition.

Cold spray has been proved to be a viable method for metallization of polymers and polymer composites. It has been reported that the mechanism of cold spray on polymeric substrates is different from the conventional mechanism on metallic substrates (i.e. adiabatic shear instability). In this work, single particle impact experiments were performed on polymeric substrates as well as mild steel. The particle-substrate interactions on different substrates were analyzed. Based on the results, the mechanism of cold spray on polymeric substrates is discussed and compared to that on metallic substrates.

In this study, high pressure cold spray (HPCS) process was used to metallize the surface of polymeric substrates to improve their mechanical performance, such as erosion, wear, and strength. Thermoplastic polymer materials (PEEK, PEI, and ABS) were used as substrate. Commercially pure (CP) Al and 7075 Al were cold sprayed onto the polymeric substrates. Good quality defect-free coatings were achieved in all combinations except with ABS substrates, which suffered from distortion during CS process due to stored thermal energy. 7075Al coatings showed high adhesion strength but low thickness (low deposition efficiency (DE)), whereas CP Al coatings revealed high thickness (high DE) but poor adhesion strength. Based on the obtained results, the DE and bonding strength are not only highly sensitive to properties of the substrate, but also to the applied process parameters as well as powder morphology. It is concluded that two separate sets of spray parameters should be applied for 7075 Al and CP Al deposition otherwise, either more damage or less bonding is achieved to the substrate. Also, for each one of these powders, the first layer of metal/polymer should be deposited with a separate recipe than the subsequent metal/metal layers. Coefficient of thermal expansion and hardness difference between the coating material and the substrate were also found to be key factors to developing continuous coatings on the polymeric substrates with the HPCS process.