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1-17 of 17
Polyether-ether-ketone composites
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Proceedings Papers
ITSC2023, Thermal Spray 2023: Proceedings from the International Thermal Spray Conference, 186-191, May 22–25, 2023,
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High-performance polymers such as poly(ether ether ketone) (PEEK) are appealing for a wide variety of industrial and medical applications due to their excellent mechanical properties. However, these applications are often limited by relatively low thermal stability and conductivity compared to metals. Many methods developed to metallize polymers, including vapor deposition and thermal spray processes, can lead to poor quality control, low deposition rate, and high cost. Thus, cold spray is a promising potential alternative to rapidly and inexpensively produce polymer-metal composites. In this study, we investigated the deposition characteristics of metalpolymer composite feedstock, composed of PEEK powder with varying volume fractions of copper (Cu) flake added, onto a PEEK substrate. We prepared the Cu-PEEK composite powder in varying compositions by two methods: hand-mixing the powders and cryogenically milling the powders. Scanning electron microscopy (SEM) of the feed mixtures shows that cryogenically milling the polymer and metal powders together created uniformly distributed micron-scale domains of Cu on PEEK particle surfaces, and vice versa, as well as consolidating much of the porous Cu flake. In lowpressure cold spray, the relatively large volume fractions of PEEK in the composite mixtures allowed for lower operating temperatures than those commonly used in PEEK metallization (300-500 °C). While the deposition efficiencies of each mixture were relatively similar in single-layer experiments, deposits formed after multiple passes showed significant changes in deposition efficiency and composition in PEEK-rich feedstock mixtures. SEM of deposit surfaces and cross-sections revealed multiple co-dominant mechanisms of deposition, which affect both the porosity and final composition of the deposit. Though present in all samples analyzed, the effects of cryogenic milling were more prevalent at lower Cu concentrations.
Proceedings Papers
ITSC2023, Thermal Spray 2023: Proceedings from the International Thermal Spray Conference, 222-228, May 22–25, 2023,
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Metallization of polymers and fiber-reinforced polymer composites is gaining attention due to the widespread application of these components in various industries, such as wind energy, aerospace, and automotive industries. Cold spray is a promising new technique to achieve the metallization of polymer and fiber-reinforced polymer composites. This work investigates the deposition mechanisms of polymer-coated metallic particles on polymer-based substrates by finite element analyses. Impact mechanics of PEEK-coated nickel particles impacting PEEK and carbon fiber-reinforced PEEK substrates are modeled. Results show the prominence of mechanical interlocking of metallic particles in the substrate, which occurs due to their entrapment inside the substrate, caused by the high energy impact-induced welding of scraped PEEK coating. The PEEK coating acts as a cushioning component, effectively mitigating the impact energy of the metallic component. The scraped PEEK coating also accumulates on the upper half of the particle, forming a cap welded to the substrate and sealing the metallic particle inside. It is observed that the depth of the carbon fiber mat in the substrate affects the mechanism and the success of deposition.
Proceedings Papers
ITSC2023, Thermal Spray 2023: Proceedings from the International Thermal Spray Conference, 280-287, May 22–25, 2023,
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A previous study on the pull-off testing of metallized carbon fiber reinforced polymers (CFRPs) via cold spray showed that better adhesion strengths could be obtained when features such as carbon fibers or surfacing elements were present, by providing potential mechanical interlocking features. In this work, the effect of the fiber orientation on the deposition and bonding of the metallic coating to the thermoplastic composite substrate is explored. Pure Sn powder was cold sprayed onto two thermoplastic Polyether-Ether- Ketone (PEEK) CFRP substrates, containing carbon fibers with different orientations: one had fibers in the plane of the substrate (uni-directional tape), while the other had fibers mostly perpendicular to the substrate (ZRT film). Characterization of the coatings was performed via scanning electron microscopy (SEM) and confocal microscopy, and some aspects of mechanical testing (namely wear and scratch testing) were carried out to assess the effect of the substrate on the properties of the coatings.
Proceedings Papers
ITSC 2022, Thermal Spray 2022: Proceedings from the International Thermal Spray Conference, 82-88, May 4–6, 2022,
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Polymer cold spray has yielded lower deposition efficiency (DE) and quality deposits compared to metal cold spray. The disparity stems from metals being studied far longer than polymers in cold spray; in addition, polymers exhibit richer thermo-mechanical behavior. An experimental study was conducted to examine the effects of polymer feedstock degree of crystallinity (D) on cold sprayed deposits of polyetherketoneketone (PEKK), a thermoplastic used in aerospace and other high-performance applications. As deposition relies on the plastic deformation of the impacting particle, polymers with high D may inhibit deposition, reducing deposit quality and efficiency. This study evaluates three PEKK grades produced using different ratios of terephthalic (T) to isophthalic (I) monomer moieties (T/I = 60/40, 70/30, 80/20). The ratios control D, with higher proportions of T monomers corresponding to higher crystallization rates and degrees of crystallinity. A parametric study was completed to evaluate functional process set points of system carrier gas temperature and powder mass flow rate. Using operational parameters common among the PEKK grades, spray cycles were completed for each material and quantitative responses to variation in crystallinity were evaluated through a suite of analyses. DE of the materials was assessed gravimetrically, deposit porosity was evaluated by scanning electron microscopy, and thermophysical changes to the feedstock during the spray cycle were determined by differential scanning calorimetry. Overall, we found that cold spray processing of powders of lower D formed less porous deposits with a higher DE than more crystalline powders sprayed at the same process conditions. PEKK grades with lower T/I ratios achieved DEs in the range of 60-75%, whereas the most T enriched grade only reached ~10% DE.
Proceedings Papers
ITSC 2022, Thermal Spray 2022: Proceedings from the International Thermal Spray Conference, 475-482, May 4–6, 2022,
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In the last 15 years, the cold spray process has demonstrated a great efficiency for the deposition of metallic powders. In this case, the consolidation of coatings is achieved thanks to the high kinetic energy of unmelted particles exhibiting a ductile behaviour. Dealing with ceramics, cold spray is also of great interest because one can expect properties not reachable with classical thermal spray technologies thanks to lower involved temperatures. However, cold spray of ceramics still remains challenging because of the ceramics intrinsic brittleness. Here, in the specific case of hydroxyapatite and to overcome this brittleness issue, we investigate the role of an intermediate PEEK layer between the substrate and the deposit. We highlight how this sublayer previously deposited by FS or air APS spraying can help improving the consolidation of the coating and its growth.
Proceedings Papers
ITSC 2021, Thermal Spray 2021: Proceedings from the International Thermal Spray Conference, 578-584, May 24–28, 2021,
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Cold Gas Spray (CGS) technology has allowed the development of biofunctional composite coatings composed of 45S5 and Polyetheretherketone (PEEK). The combination of a bioactive glass material embedded in a biocompatible polymeric matrix becomes this new composite in an interesting material for orthopedic applications since meet the biomechanical and biological requirements of an artificial implant. In the present study, blends of bioactive glass 45S5 and PEEK powder with different granulometry and 45S5/PEEK ratio have been prepared. These mixtures of powders have been deposited onto PEEK substrates by CGS with the goal of incorporating a bioactive additive to the biocompatible polymer, which can improve the bone-implant interaction of PEEK. The deposition efficiency (DE) and thickness of the coatings have been evaluated and from the results obtained, it was possible to conclude that DE and coating thickness are significantly affected by the granulometry and by the 45S5/PEEK ratio of the blends. By Scanning Electron Microscopy (SEM) inspection, it was observed that the use of blends with high 45S5/PEEK ratio led to the deposition of coatings with high content of 45S5 particles embedded in the polymeric matrix. Finally, the friction behavior of the coatings was analyzed performing ball-on-disk tests and these experiments showed that the presence of glass particles has a beneficial role in the wear resistance of the coatings.
Proceedings Papers
ITSC 2019, Thermal Spray 2019: Proceedings from the International Thermal Spray Conference, 557-562, May 26–29, 2019,
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This work addresses some of the challenges associated with depositing copper on PEEK by cold spraying. Getting copper powder to adhere to the PEEK substrate is not difficult at first, but deposition efficiency falls rapidly during coating build-up. Without heating the propellant gas, a copper coating will not form, even at the highest gas pressures. Increasing prechamber pressure is necessary, but requires an increase in gas temperature to 400°C to reach a deposition efficiency of 70%. Subjecting PEEK to such heat causes delamination issues that offset the deposition efficiency gained.
Proceedings Papers
ITSC 2017, Thermal Spray 2017: Proceedings from the International Thermal Spray Conference, 98-103, June 7–9, 2017,
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Previous results at McGill University have shown that metallic coatings can be successfully cold sprayed onto polymeric substrates. This paper studies the cold sprayability of various metal powders on different polymeric substrates. Five different substrates were used, including carbon fibre reinforced polymer (CFRP), acrylonitrile butadiene styrene (ABS), polyether ether ketone (PEEK), polyethylenimine (PEI); mild steel was also used as a bench mark substrate. The CFRP used in this work has a thermosetting matrix, and the ABS, PEEK, and PEI are all thermoplastic polymers, with different glass transition temperatures as well as a number of distinct mechanical properties. Three metal powders, tin, copper and iron, were cold sprayed with both a low-pressure system and a high-pressure system at various conditions. In general, cold spray on the thermoplastic polymers rendered more positive results than the thermosetting polymers, due to the local thermal softening mechanism in the thermoplastics. Thick copper coatings were successfully deposited on PEEK and PEI.
Proceedings Papers
ITSC2016, Thermal Spray 2016: Proceedings from the International Thermal Spray Conference, 437-443, May 10–12, 2016,
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In this work, copper and PEEK powder mixtures are cold sprayed onto carbon fiber-reinforced polymer (CFRP) substrates with the aim of producing a well-adhered conductive layer. The composite coatings were optimized through the study of the deposited mass and its dependence on process parameters and Cu powder morphology. A morphological model based on Cu phase data was developed to better understand coating microstructures. Coatings synthesized from irregular Cu particles were found to be electrically conductive, while those containing spherical Cu particles were insulating. These phenomena are explained using the developed simulation tools coupled with the investigation of coating build-up and microstructure.
Proceedings Papers
ITSC 2013, Thermal Spray 2013: Proceedings from the International Thermal Spray Conference, 91-96, May 13–15, 2013,
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This paper presents a summary of some of the research conducted on sponge-like titanium coatings developed for orthopedic use. It assesses the pore structure, adhesion properties, and in-vitro and in-vivo biological characteristics of porous titanium coatings deposited by vacuum plasma spraying on metals, PEEK polymer, and two bioceramics, Mg-toughened ZrO 2 and ZrO 2 -toughened Al 2 O 3 . The plasma sprayed coatings show good flexibility in terms of pore size (100-800 µm), overall porosity (40-70%), and coating thickness (600-1500 µm).
Proceedings Papers
ITSC 2008, Thermal Spray 2008: Proceedings from the International Thermal Spray Conference, 971-974, June 2–4, 2008,
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Thermal spray of polymers has had limited investigation due to the narrow processing windows that are inherent to polymer powders, especially their low temperatures of thermal degradation. The polymer poly aryl ether ether ketone (PEEK) has a high thermal degradation temperature and high resistance to alkaline and acidic attack. These properties led to PEEK being selected for investigation. To minimise thermal degradation of the particles, the high velocity air fuel (HVAF) technique was used. To investigate the effect of substrate pre-treatment on single splat properties, single splats were collected on aluminium 5052 substrates with six different pretreatments. The single splats collected were imaged by scanning electron microscopy (SEM) and image analysis was performed with ImageJ, an open source scientific graphics package. On substrates held at 323°C it was found that substrate pretreatment had a significant effect on the circularity and area of single splats, and also on the number of splats deposited on the substrates. Increases in splat circularity, area, and the number of splats deposited on the surface were linked to the decrease in chemisorbed water on the substrate surface and the decrease of surface roughness. This proved that surface chemistry and roughness are crucial to forming single splats with good properties, which will lead to coatings of good properties.
Proceedings Papers
Valence Band XPS and FT-IR Evaluation of Thermal Degradation of HVAF Thermally Sprayed PEEK Coatings
ITSC 2008, Thermal Spray 2008: Proceedings from the International Thermal Spray Conference, 1069-1071, June 2–4, 2008,
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Coatings of poly(ether-ether-ketone) (PEEK) have been produced using the high-velocity air fuel (HVAF) thermal spray technique. These coatings have been produced at 50 and 100 mm nozzle lengths and 200, 300, and 400 mm gun-to-substrate distances on stainless steel 304 substrates. The techniques used to characterize and determine the extent of thermal degradation of the PEEK coatings were valence-band XPS and FTIR-ATR. Valence-band XPS showed that, in general, minimal degradation of the PEEK occurred during the HVAF thermal spraying process. FTIR-ATR results showed that more surface degradation of the PEEK coating occurred at the 200 mm gun-to-substrate distance for both nozzle lengths than at the larger gun-to-substrate distances. Specifically, absorption bands appeared at 2918 and 2850 cm -1 , which correspond to alkane –CH 2 – asymmetric stretching modes. The resolution of the 672 cm -1 peak, which corresponds to C–H vibrations on the phenyl ring, increased from one to two peaks in the spectra of the 200 and 300 mm gun-to-substrate runs. This indicates a structural change in the phenyl ring, possibly indicating a change in the extent of crystallization of the PEEK polymer.
Proceedings Papers
ITSC 2007, Thermal Spray 2007: Proceedings from the International Thermal Spray Conference, 371-376, May 14–16, 2007,
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New advanced polymeric biomaterials such as implantable poly(etheretherketone) (PEEK) are changing the face of the implantable medical device industry. Due to its bioactive behavior in vivo, hydroxyapatite (HA) coatings are used to improve the bone growth and to repair around metallic implant. The objective of this work is to study the feasibility of plasma sprayed hydroxyapatite coating on PEEK material. Different PEEK (unfilled and composite) specimens were successfully coated with a 150 µm thick coating. Chemical and crystallographic compositions, adhesions and microstructures of HA coatings on PEEK and on Ti-6Al-4V were compared. The results showed that the structure of HA coatings were appreciably equivalent. Mechanical tests showed that the plasma spraying process did not severely degrade the initial properties of the PEEK substrate.
Proceedings Papers
ITSC 2006, Thermal Spray 2006: Proceedings from the International Thermal Spray Conference, 923-928, May 15–18, 2006,
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Flame sprayed PEEK (poly-ether-ether-ketone) coatings, with an amorphous structure, were subjected to isothermal treatments with annealing temperatures from 180 to 300 °C and holding time from 1 to 30 min. The coating structures were studied by means of DSC (Differential Scanning Calorimetry) and XRD (X-Ray Diffraction) analyses. All annealed coatings exhibit semi-crystalline structures. Coexistence of thick and thin lamellae in the spherulites of annealed coatings can be deduced from the analysis results. The Knoop hardness and the interfacial adhesion of the coatings were examined. The annealed coatings exhibit higher hardness than the amorphous ones. The formation of the thick lamellae is the determinant factor for improving the coating hardness. However, the annealed coatings exhibit a weak adherence to the substrate. Some fissures or spherical porosities could be observed, in certain zones, on the coating/substrate interface. The formation of these fissures and porosities could be ascribed to the coating residual stress and the big volume contraction during the crystallisation that occurred under the annealing condition.
Proceedings Papers
ITSC 2006, Thermal Spray 2006: Proceedings from the International Thermal Spray Conference, 935-940, May 15–18, 2006,
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PEEK was sprayed with a Browning Aerospray HVAF thermal spray gun to enable the study of the wetting and interaction of single splats with an aluminium 5005 substrate. Single splats were obtained by exposing the substrate to the spray flame for 0.02 s by dropping a steel shutter with a 25 mm aperture milled in the centre. The single splats were then analysed through SEM (scanning electron microscopy) and FIB microscopy (focussed ion beam). Splat shape was found to be dependant on nozzle length, with a 100 mm nozzle resulting in more splashing, and a 450 mm spray distance providing more disc splats. PEEK splats do not wet the aluminium oxide surface well. Porosity occurs independently of nozzle length, in the form of cracks and pores in the splats, some cracks completely segmenting a splat.
Proceedings Papers
ITSC 2005, Thermal Spray 2005: Proceedings from the International Thermal Spray Conference, 732-737, May 2–4, 2005,
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Amorphous PEEK coating was prepared on Al substrate, employing flame spraying technology. The amorphous coating was subjected to annealing treatments under different conditions. Both differential scanning calorimetry (DSC) and wide angle X-ray diffraction (WAXD) analysis revealed that the isothermally treated coating exhibited semi-crystalline structure. Coexistence of double crystal entities in semi-crystalline PEEK coating was deduced from the results obtained by DSC and WAXD measurements. Annealing temperature and holding time under this temperature affect the morphology of the minor crystal entity which is metastable. The mechanical properties of the isothermally treated coating were investigated considering coating microhardness and friction and wear properties. The variations of the coating mechanical properties were correlated with the modifications in the coating structure induced by the different annealing conditions.
Proceedings Papers
ITSC1999, Thermal Spray 1999: Proceedings from the United Thermal Spray Conference, 582-587, March 17–19, 1999,
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Thermally sprayed coatings made of polyetheretherketone (PEEK) and polyphenylene sulfide (PPS) are becoming increasingly interesting, especially for corrosion protection applications at elevated temperatures in the chemical industry. In contrast to conventional polymers these materials melt at much higher temperatures. Furthermore, PPS and PEEK show enhanced mechanical and chemical stability. Instead of HVOF and plasma spraying, in this paper much simpler and low-cost flame spraying is used because of these advantages. The polymers are investigated along the entire deposition process in order to exclude possible decomposition. Attempts are made with various adhesive layers to reduce the unacceptably high preheat temperatures. The corrosion protection features are examined by means of corrosion tests with various media. The results of the experiments presented in this paper promise coatings of high performance thermoplasts a great future as anticorrosive coatings. Paper includes a German-language abstract.