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Deposition of Electrically Conductive Coatings on Castable Polyurethane Elastomers by the Flame Spraying Process

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Abstract

Deposition of metallic coatings on elastomeric polymers is a challenging task due to the heat sensitivity and soft nature of these materials and the high temperatures in thermal spraying processes. In this study, a flame spraying process was employed to deposit conductive coatings of aluminum-12silicon on polyurethane elastomers. The effect of process parameters, i.e., stand-off distance and air added to the flame spray torch, on temperature distribution and corresponding effects on coating characteristics, including electrical resistivity, were investigated. An analytical model based on a Green’s function approach was employed to determine the temperature distribution within the substrate. It was found that the coating porosity and electrical resistance decreased by increasing the pressure of the air injected into the flame spray torch during deposition. The latter also allowed for a reduction of the stand-off distance of the flame spray torch. Dynamic mechanical analysis was performed to investigate the effect of the increase in temperature within the substrate on its dynamic mechanical properties. It was found that the spraying process did not significantly change the storage modulus of the polyurethane substrate material.

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Abbreviations

A, B :

Constants describing the back temperature of the substrate (T = At + B)

k :

Thermal conductivity (W/m·K)

L :

Substrate thickness (m)

n :

Summation index

q″ AVG :

Average heat flux (W/m2)

t :

Time (s)

T :

Temperature (°C)

x :

Coordinate (m)

α :

Thermal diffusivity (m2/s)

λ :

Eigenvalue (m−1)

∞:

Infinity

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Acknowledgments

Support for this Project was provided by the Natural Sciences and Engineering Research Council of Canada (NSERC) and Syncrude Canada Limited.

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Authors and Affiliations

  1. Department of Mechanical Engineering, University of Alberta, Edmonton, AB, T6G 1H9, Canada

    H. Ashrafizadeh, A. McDonald & P. Mertiny

Authors
  1. H. Ashrafizadeh
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  3. P. Mertiny
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Correspondence to P. Mertiny.

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Ashrafizadeh, H., McDonald, A. & Mertiny, P. Deposition of Electrically Conductive Coatings on Castable Polyurethane Elastomers by the Flame Spraying Process. J Therm Spray Tech 25, 419–430 (2016). https://doi.org/10.1007/s11666-015-0376-2

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  • DOI: https://doi.org/10.1007/s11666-015-0376-2

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