Cold spray deposition of metallic coatings on polymers: a review

Abstract

Cold spray deposition, which can be framed in the wider family of additive manufacturing, is a manufacturing technique that is able to produce coatings on diverse types of substrates through the deposition of feedstock powder. As a low-temperature process, cold spray represents a potential solution for the metallization of temperature-sensitive materials, i.e. polymers and polymer matrix composites. The study of the cold spray technology for the metallization of polymers is still in its early stage, and the deposition mechanisms of metals on polymer-based materials are not thoroughly understood yet. On these premises, a review on this topic is needed to systematically depict the actual state of the art and to provide a reliable and well-organized overview discussing all the theories arisen in these years. In summary, this review aims: i) to collect all the available literature and enucleate the most discussed and interesting points (the most prevailing theories regarding the bonding mechanisms, the influence of the different process parameters and the main characteristics of cold-sprayed coating), providing a reliable and well-organized state of the art; ii) to define the open questions and to delineate the directions of future work.

A State-of-the-Art Review on 4D Printed Antennas and Other Adaptable Designs

“…Additionally, transmission lines, radiative structures like patches, and horn antennas can be created by metallizing 3D printed polymer substrates. Metallization techniques encompass various methods such as physical vapor deposition (PVD) [59], spray coating [32], aerosol jet printing [60], electroless plating and electroplating [61], and other similar processes. When employed, these techniques drastically enhance surface electrical conductivity and significantly improve radiation efficiency by reducing losses and enhancing matching.…”

“…Currently, the predominant 3D printing techniques used for the creation of printed smart materials are FDM, SLA, SLS, direct ink writing (DIW), and digital light processing (DLP). However, other printing methods such as inkJet printing (IJP) [31], Cold spray deposition [32], twophoton polymerization lithography (TPL), laser direct writing (LDW) and projection micro-stereolithography (PµSL) are also pointed out in the literature for the production of printed smart materials [16], [19], [20], [27].…”

A machine learning approach for adhesion forecasting of cold-sprayed coatings on polymer-based substrates

“…Although this technology has been widely explored and employed on metal substrates, the underlying physics when the substrate is a polymer is yet unclear [3]. Because the final coating characteristics (such as powder deformation or penetration depth, which are closely related to coating adhesion) depend on a variety of factors, including the properties of the metallic powder and the polymeric substrates, as well as the spraying parameters set for the process, it is currently impossible to accurately predict how the metallic particles will behave when they impact on various substrates.…”

Determination of Critical Velocity of Cold-Sprayed NiCoCrAlY Coating via Arbitary Lagrangian-Eulerian (ALE) Method of Finite Element Simulation

“…In this process, the powder particles (usually 5~50 µm in diameter) are accelerated to a high speed (typically 300~1200 m/s), and they undergo intense plastic deformation [2,3]. In recent years, the deposition and preparation of various materials, such as pure metals, metal alloys, composites and some ceramic materials can be obtained via the cold spray process [4][5][6]. Cold spray technology has the characteristics of low deposition temperature, low porosity, low oxygen content, high bonding strength and high hardness of the deposited layer [7][8][9], which is commonly used in surface repair, surface enhancement, additive manufacturing of metal and alloy parts, etc.…”