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Electrical Conductivity of Metal–Polymer Cold Spray Composite Coatings onto Carbon Fiber-Reinforced Polymer

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Abstract

Cold spray is a promising process to coat polymers and carbon fiber-reinforced polymer (CFRP). The choice of the metal–polymer couple of materials, however, has a strong influence on coating buildup and properties. In the present work, we show that spraying mixtures of copper and polymer particles lead to composite coating. We observe that the polymer promotes coating buildup onto CFRP to the expense of the electrical conductivity of the coating as a result of its insulating properties. The present work investigates the influence of the coating microstructure on electrical conductivity. Various copper powders, with different morphologies, particle sizes and oxygen contents were mixed with a polyaryl-ether-ether-ketone (PEEK) powder. Cold spray of these powders resulted into composite coatings, and we study the microstructures and electrical properties of such coatings as a function of powder characteristics and spraying parameters. A morphological model of the coating microstructure was developed to reproduce numerically microstructures in 3D. The conductivity of the coatings was measured experimentally for various copper powders. Careful selection of blends of copper and PEEK powders coupled with optimized spraying parameters led to metal–polymer coatings onto CFRP with a fairly high electrical conductivity.

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Acknowledgments

This work was carried out within the “C.O.MET” FUI program. The authors would like to thank the members of the program consortium (under coordination of Dassault Aviation/Argenteuil-France) and BPI France, Pôle Astech, Pôle de la céramique, Pôle des microtechniques and DGAC for financial support. BF and FW were supported by grant No FA9550-15-10461 DE from the Air Force Office of Scientific Research (AFOSR).

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Authors and Affiliations

  1. Centre for Materials, Mines ParisTech - PSL Research University, 91003, Evry, France

    Vincent Bortolussi, François Willot & Michel Jeandin

  2. Centre for Mathematical Morphology, Mines ParisTech - PSL Research University, 77300, Fontainebleau, France

    Bruno Figliuzzi, François Willot & Matthieu Faessel

Authors
  1. Vincent Bortolussi
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  2. Bruno Figliuzzi
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  3. François Willot
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  4. Matthieu Faessel
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  5. Michel Jeandin
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Correspondence to Vincent Bortolussi.

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Bortolussi, V., Figliuzzi, B., Willot, F. et al. Electrical Conductivity of Metal–Polymer Cold Spray Composite Coatings onto Carbon Fiber-Reinforced Polymer. J Therm Spray Tech 29, 642–656 (2020). https://doi.org/10.1007/s11666-020-00999-7

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  • DOI: https://doi.org/10.1007/s11666-020-00999-7

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