Cold Spray Deposition of Nylon-6 on Glass Fiber-Reinforced Composites

Abstract

This work investigates the cold spray deposition of thermoplastic powders on fiber-reinforced polymer−matrix composites using a combined experimental-computational approach. Cold spray deposition of nylon-6 powders on woven glass fiber-reinforced composite panels is successfully achieved by the proper identification of two critical process parameters, particle temperature and impact velocity. Experimental evaluations indicate that the bonding between the deposited nylon layers and the composite substrate is achieved primarily due to the concurrent severe plastic deformation of the powders and the surface epoxy layer on the substrate, leading to the development of acceptable bond strengths. Finite element simulations reveal the fundamental impact mechanics of the process while ensuring that the impact-induced damage to the reinforcing fibers can be minimal, provided that the cold spray process parameters are selected properly. Results presented herein highlight polymer cold spray as a promising surface coating and functionalization process applicable to polymer−matrix composites.