Skip to main content
SpringerLink
Log in

Observation of an Indirect Deposition Effect while Cold Spraying Sn-Al Mixed Powders onto Carbon Fiber Reinforced Polymers

  • Peer Reviewed
  • Published:
Journal of Thermal Spray Technology Aims and scope Submit manuscript

Abstract

Single-component tin coatings have successfully been cold sprayed onto carbon fiber reinforced polymers in previous studies at McGill University. Coatings with mixed metal powders were also sprayed to improve the deposition efficiency and coating conductivity. The results indicated a noticeable improvement in deposition efficiency related to the addition of a secondary metallic powder (aluminum, copper and zinc); this study is focused on the effect of aluminum. Following cold spray of various Sn/Al mixtures over a wide range of gas pressures, unusual coating morphologies were observed. The study of these morphologies leads to the description of two distinct deposition phases depending on the spray pressure: a direct deposition effect and an indirect deposition effect. The presence of submicron particles also supports the occurrence of a powder melting phenomenon during the process. Numerical simulations were conducted to support the description of these phenomena.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15

Similar content being viewed by others

References

  1. Handbook-Airframe, Aviation Maintenance Technician Vol. 1,. US Department of Transportation, Federal Aviation Administration, 2018 (Oklahoma City, OK), p 7–6

  2. A. Larsson, A. Delannoy, and P. Lalande, Voltage Drop Along a Lightning Channel During Strikes to Aircraft, Atmos. Res., 2005, 76(1–4), p 377-385

    Article  Google Scholar 

  3. M. Menningen and H. Weiss, Application of Fracture Mechanics to the Adhesion of Metal Coatings on CFRP, Surf. Coat. Technol., 1995, 76–77, p 835-840

    Article  Google Scholar 

  4. H. Che, M. Gagné, P.S.M. Rajesh, J.E. Klemberg-Sapieha, F. Sirois, D. Therriault, and S. Yue, Metallization of Carbon Fiber Reinforced Polymers for Lightning Strike Protection, J. Mater. Eng. Perform., 2018, 27(10), p 5205-5211

    Article  CAS  Google Scholar 

  5. G. Archambault, B. Jodoin, S. Gaydos, and M. Yandouzi, Metallization of Carbon Fiber Reinforced Polymer Composite by Cold Spray and Lay-Up Molding Processes, Surf. Coat. Technol., 2016, 300, p 78-86

    Article  CAS  Google Scholar 

  6. R. Wang, D. Song, W. Liu, and X. He, Effect of Arc Spraying Power on the Microstructure and Mechanical Properties of Zn-Al Coating Deposited onto Carbon Fiber Reinforced Epoxy Composites, Appl. Surf. Sci., 2010, 257(1), p 203-209

    Article  CAS  Google Scholar 

  7. J. Affi, H. Okazaki, M. Yamada, and M. Fukumoto, Fabrication of Aluminum Coating onto CFRP Substrate by Cold Spray, Mater. Trans., 2011, 52(9), p 1759-1763

    Article  CAS  Google Scholar 

  8. H. Che, X. Chu, P. Vo, and S. Yue, Metallization of Various Polymers by Cold Spray, J. Therm. Spray Technol., 2017, 27(1–2), p 169-178

    Google Scholar 

  9. H. Che, P. Vo, and S. Yue, Metallization of Carbon Fibre Reinforced Polymers by Cold Spray, Surf. Coat. Technol., 2017, 313, p 236-247

    Article  CAS  Google Scholar 

  10. R. Lupoi and W. O’Neill, Deposition of Metallic Coatings on Polymer Surfaces using Cold Spray, Surf. Coat. Technol., 2010, 205(7), p 2167-2173

    Article  CAS  Google Scholar 

  11. A. Sturgeon, B. Dunn, S. Celotto, and B. O’Neill, Cold Sprayed Coatings for Polymer Composite Substrate, Proceedings of the 10th ISMSE, 8th ICPMSE, on CD-ROM, B. Battrick, Ed., June 19-23, 2006 (Collioure, France), ESA Publications Division (2006)

  12. A. Ganesan, M. Yamada, and M. Fukumoto, The Effect of CFRP Surface Treatment on the Splat Morphology and Coating Adhesion Strength, J. Therm. Spray Technol., 2013, 23(1–2), p 236-244

    Google Scholar 

  13. D. Zhang, P.H. Shipway, and D.G. McCartney, Cold Gas Dynamic Spraying of Aluminum: The Role of Substrate Characteristics in Deposit Formation, J. Therm. Spray Technol., 2005, 14(1), p 109-116

    Article  Google Scholar 

  14. H.Y. Lee, Y.H. Yu, Y.C. Lee, Y.P. Hong, and K.H. Ko, Cold Spray of SiC and Al2O3 With Soft Metal Incorporation: A Technical Contribution, J. Therm. Spray Technol., 2004, 13(2), p 184-189

    Article  CAS  Google Scholar 

  15. E. Irissou, J.-G. Legoux, B. Arsenault, and C. Moreau, Investigation of Al-Al2O3 Cold Spray Coating Formation and Properties, J. Therm. Spray Technol., 2007, 16(5–6), p 661-668

    Article  CAS  Google Scholar 

  16. H. Koivuluoto and P. Vuoristo, Effect of Powder Type and Composition on Structure and Mechanical Properties of Cu + Al2O3 Coatings Prepared by using Low-Pressure Cold Spray Process, J. Therm. Spray Technol., 2010, 19(5), p 1081-1092

    Article  CAS  Google Scholar 

  17. H. Che, X. Chu, P. Vo, and S. Yue, Cold Spray of Mixed Metal Powders on Carbon Fibre Reinforced Polymers, Surf. Coat. Technol., 2017, 329, p 232-243

    Article  CAS  Google Scholar 

  18. A. Liberati, H. Che, P. Vo, and S. Yue, Cold Spraying of Mixed Sn-Al Powders onto Carbon Fibre Reinforced Polymers, in F. Azarmi, K. Balani, T. Eden, T. Hussain, Y.-C. Lau, H. Li, K. Shinoda (Eds.), ITSC 2018—Proceedings of the International Thermal Spray Conference, May 7-10, 2018 (Orlando, Florida), ASM International, p 166–172 (2018)

  19. R. Lupoi and W. O’Neill, Powder Stream Characteristics in Cold Spray Nozzles, Surf. Coat. Technol., 2011, 206(6), p 1069-1076

    Article  CAS  Google Scholar 

  20. M. Meyer and R. Lupoi, An Analysis of the Particulate Flow in Cold Spray Nozzles, Mech. Sci., 2015, 6(2), p 127-136

    Article  Google Scholar 

  21. B. Samareh, O. Stier, V. Lüthen, and A. Dolatabadi, Assessment of CFD Modeling via Flow Visualization in Cold Spray Process, J. Therm. Spray Technol., 2009, 18(5), p 934

    Article  CAS  Google Scholar 

  22. H. Tabbara, S. Gu, D.G. McCartney, T.S. Price, and P.H. Shipway, Study on Process Optimization of Cold Gas Spraying, J. Therm. Spray Technol., 2010, 20(3), p 608-620

    Article  Google Scholar 

  23. C. Zhang, Q. Chen, J. Liu, W. Tang, K. Wang, and J. Song, Numerical Study on the Effect of the Cold Powder Carrier Gas on Powder Stream Characteristics in Cold Spray, Surf. Coat. Technol., 2016, 294, p 177-185

    Article  CAS  Google Scholar 

  24. Mx Surface Texture Parameters, Zygo, AMETEK Inc. (2018)

  25. C. Gomez, R. Su, A. Thompson, J. DiSciacca, S. Lawes, and R.K. Leach, Optimization of Surface Measurement for Metal Additive Manufacturing using Coherence Scanning Interferometry, Opt. Eng., 2017, 56(11), p 111714-1-8

    Article  Google Scholar 

  26. Fluent 6.3 User’s Guide, Fluent Inc. (2006)

  27. T. Schmidt, F. Gärtner, H. Assadi, and H. Kreye, Development of a Generalized Parameter Window for Cold Spray Deposition, Acta Mater., 2006, 54(3), p 729-742

    Article  CAS  Google Scholar 

Download references

Acknowledgments

The authors wish to acknowledge the financial support of the Natural Sciences and Engineering Research Council of Canada (NSERC) through the Green-SEAM strategic network and the McGill Engineering Doctoral Award (MEDA). The industrial partner, Bombardier Aerospace, is gratefully acknowledged. Mr. Marco Zeman from National Research Council Canada, Boucherville, is acknowledged for his contribution to the cold spray experiments.

Author information

Authors and Affiliations

  1. Mining and Materials Engineering, McGill University, Montreal, QC, Canada

    Andre C. Liberati, Hanqing Che & Stephen Yue

  2. National Research Council Canada, Boucherville, QC, Canada

    Phuong Vo

Authors
  1. Andre C. Liberati
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Hanqing Che
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Phuong Vo
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Stephen Yue
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding authors

Correspondence to Andre C. Liberati or Hanqing Che.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Liberati, A.C., Che, H., Vo, P. et al. Observation of an Indirect Deposition Effect while Cold Spraying Sn-Al Mixed Powders onto Carbon Fiber Reinforced Polymers. J Therm Spray Tech 29, 134–146 (2020). https://doi.org/10.1007/s11666-019-00967-w

Download citation

  • Received:

  • Revised:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11666-019-00967-w

Keywords

Search

Navigation