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<p>Interfacial bonding in cold-sprayed polymer and composite deposits depends on complex mechanisms that remain insufficiently understood, limiting component reliability under extreme conditions encountered in aerospace and automotive systems. The present study addresses this knowledge gap by elucidating the bonding mechanisms in high-performance poly(ether-ether-ketone) (PEEK)-boron nitride nanoplatelet (BNNP) nanocomposites. Single-splat studies of pure PEEK and PEEK-BNNP composite particles, combined with microstructural, spectroscopic, and mechanical characterization, were conducted to elucidate particle–substrate interactions, revealing that impact-induced plastic deformation and molecular-level chemical interactions drive splat bonding. Knowledge from these single-impact studies was applied to fabricate bulk PEEK and PEEK-BNNP deposits using identical deposition parameters, enabling correlation between splat-scale bonding and deposit consolidation. Fourier-transform infrared spectroscopy confirmed interfacial chemical bonding through O–H···O=C and B–O linkages between PEEK chains and BNNPs. Incorporation of BNNPs increased deposition efficiency from 88% to 95%, enhanced hardness by 243%, and raised the elastic modulus by 62% due to their ability to promote interparticle bonding and stress transfer during impact. Thermal analysis revealed an 18% improvement in the degradation temperature, indicating superior thermal stability. These findings establish the mechanistic relationship between impact-driven densification, interfacial bonding, and the resulting mechanical and thermal properties, advancing cold spray for durable, high-temperature PEEK-based nanocomposite deposits.</p>

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Bonding Mechanisms Governing Mechanical and Thermal Properties of Cold Sprayed Poly(Ether-Ether-Ketone)-Boron Nitride Nanocomposite Deposits

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年6月17日

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  • Suleiman Muktari,
  • Luiza Benedetti,
  • Denny John,
  • Anil Lama,
  • Tyler Dolmetsch,
  • Rony Thomas Murickan,
  • Abhijith Kunneparambil Sukumaran,
  • Benjamin Boesl,
  • Arvind Agarwal,
  • Tanaji Paul

摘要

Interfacial bonding in cold-sprayed polymer and composite deposits depends on complex mechanisms that remain insufficiently understood, limiting component reliability under extreme conditions encountered in aerospace and automotive systems. The present study addresses this knowledge gap by elucidating the bonding mechanisms in high-performance poly(ether-ether-ketone) (PEEK)-boron nitride nanoplatelet (BNNP) nanocomposites. Single-splat studies of pure PEEK and PEEK-BNNP composite particles, combined with microstructural, spectroscopic, and mechanical characterization, were conducted to elucidate particle–substrate interactions, revealing that impact-induced plastic deformation and molecular-level chemical interactions drive splat bonding. Knowledge from these single-impact studies was applied to fabricate bulk PEEK and PEEK-BNNP deposits using identical deposition parameters, enabling correlation between splat-scale bonding and deposit consolidation. Fourier-transform infrared spectroscopy confirmed interfacial chemical bonding through O–H···O=C and B–O linkages between PEEK chains and BNNPs. Incorporation of BNNPs increased deposition efficiency from 88% to 95%, enhanced hardness by 243%, and raised the elastic modulus by 62% due to their ability to promote interparticle bonding and stress transfer during impact. Thermal analysis revealed an 18% improvement in the degradation temperature, indicating superior thermal stability. These findings establish the mechanistic relationship between impact-driven densification, interfacial bonding, and the resulting mechanical and thermal properties, advancing cold spray for durable, high-temperature PEEK-based nanocomposite deposits.