Cold spray on short carbon fiber reinforced PEEK substrates
摘要
This work focuses on the metallization of short carbon fiber reinforced PEEK composites by the cold spray technology. In this process, powder particles are accelerated to high speeds by a heated and pressurized gas. Particles maintain their solid state all along the process. The main challenges identified in previous studies on the topic concern the low adhesion of metal coatings onto polymer-based composites and the risk of damaging the composite during the cold spray process. The innovative strategy employed in this study consists in spraying a mixed Al-PEEK feedstock powder, with different PEEK proportions within the mixture. Both high-pressure and low-pressure cold spray systems have been tested for comparison. The principal outcomes of the study can be summarized as follows: coatings produced by low-pressure cold spray can achieve higher adhesion values; the higher the spraying temperature, the higher the adhesion; an increased PEEK content in the feedstock results in higher adhesion, at the expense of lower electrical conductivity. When PEEK content in the feedstock passes a certain threshold, located between 10 and 20 vol.%, the coatings completely lack electrical conductivity. A compromise thus has to be found, depending on the requirement of each application, to achieve a satisfying balance between the antagonist properties of adhesion and electrical conductivity. Finally, two mechanisms leading to coating creation and growth for mixed metal-polymer feedstock powders have been proposed.