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Development of Ultra-High Molecular Weight Polyethylene (UHMWPE) Coating by Cold Spray Technique

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Abstract

Ultra-high molecular weight polyethylene or UHMWPE is an extremely difficult material to coat with, as it is rubbery and chemically very inert. The Cold Spray process appears to be a promising alternative processing technique but polymers are in general difficult to deposit using this method. So, attempts to develop UHMWPE coatings were made using a downstream injection cold spray technique incorporating a few modifications. A conventional cold spray machine yielded only a few deposited particles of UHMWPE on the substrate surface, but with some modifications in the nozzle geometry (especially the length and inner geometry) a thin coating of 45 μm on Al substrate was obtained. Moreover, experiments with the addition of fumed nano-alumina to the feedstock yielded a coating of 1-4 mm thickness on Al and polypropylene substrates. UHMWPE was seen to be melt crystallized during the coating formation, as can be seen from the differential calorimetry curves. Influence of nano-ceramic particles was explained by observing the creation of a bridge bond between UHMWPE particles.

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Abbreviations

Gwt.%:

Weight percentage of guest particles

D :

Average diameter of host particle (m)

d :

Average diameter of guest particles (m)

ρD :

Density of host particles (kg/m3)

ρd :

Density of the guest particles (kg/m3)

ΔE :

Energy required for melting one particle (kg m2/s2)

ΔH :

Melting enthalpy of the crystal (m2/s2)

\(X_{\text{c}}\) :

Crystallinity of the nascent powder

C p :

Heat capacity (m2/s2/K)

m :

Mass of the UHMWPE particle (kg)

r :

Radius of the UHMWPE particle (m)

E c :

Kinetic energy of the UHMWPE particle (kg m2/s2)

V :

Velocity of the UHMWPE particle (m/s)

ΔT :

Temperature change (K)

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Acknowledgments

The authors are indebted to Ticona (Oberhausen, Germany) for the generous supply of the UHMWPE sample together with its molecular characteristics. One of us, Tiana Deplancke acknowledges ONR (USA) for its financial support through the NICOP project. Authors would also like to thank JTSS internship program for financing and supporting the internship, carried out at Iwate Industrial Research Institute. This work was partly supported by the JSPS Core-to-Core Program, A. Advanced Research Networks, “International research core on smart layered materials and structures for energy saving.” Authors would also like to thank Prof. Hidemasa Takana from Institute of Fluid Science (Tohoku University) for his valuable insights to understanding the flow dynamics within the nozzles.

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Authors and Affiliations

  1. Fracture and Reliability Research Institute, Tohoku University, 6-6-11-720, Aoba, Aramaki, Aoba-ku, Sendai, 980-8579, Japan

    Kesavan Ravi, Yuji Ichikawa & Kazuhiro Ogawa

  2. Materials Engineering and Science (MATEIS), CNRS, INSA-Lyon UMR5510, Université de Lyon, 69621, Villeurbanne, France

    Tiana Deplancke, Olivier Lame & Jean-Yves Cavaille

Authors
  1. Kesavan Ravi
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  2. Yuji Ichikawa
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  3. Tiana Deplancke
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  4. Kazuhiro Ogawa
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  5. Olivier Lame
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  6. Jean-Yves Cavaille
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Correspondence to Kesavan Ravi.

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Ravi, K., Ichikawa, Y., Deplancke, T. et al. Development of Ultra-High Molecular Weight Polyethylene (UHMWPE) Coating by Cold Spray Technique. J Therm Spray Tech 24, 1015–1025 (2015). https://doi.org/10.1007/s11666-015-0276-5

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  • DOI: https://doi.org/10.1007/s11666-015-0276-5

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