Integrating 3D printing of polymer matrix composites and metal additive layer manufacturing: surface metallization of 3D printed composite panels through cold spray deposition of aluminium particles

Abstract

The integration of metals and polymers in the same component to couple the best properties and advantages of both these classes of materials can be useful for engineering applications. In this scenario, the aim of this paper is to integrate additive manufacturing of composites with cold spray deposition of metal particles: in particular, 3D-printed carbon fibre-reinforced plastics (CFRP) panels were coated with aluminium particles to couple the lightweight and high mechanical properties of CFRP with high wear resistance and hardness of metals. CFRP panels have been produced by using the Fused Filament Fabrication (FFF) technology, then the panels have been coated with aluminium particles by using a low pressure cold spray facility. Panels with various stratification sequences have been produced to investigate the feasibility of the process and to highlight the influence of the lay-up strategy on the whole process; the parameters of the cold spray process have been also optimized to ensure an effective deposition. Adhesion tests, distortion measurements, cross-section observations and surface coverage measurements have been chosen as response outputs to evaluate the effectiveness of the process and to assess the influence of the process parameters. The integration between FFF of CFRPs and cold spray deposition of aluminium particles has been proved, values of surface coverage close to 100% and good values of adhesion strength (close to 4 MPa) have been achieved; moreover, the presence of the fibres, giving a higher stiffness to the substrate, avoids the occurrence of distortion phenomena during the deposition. It was also proved that the printing parameters influence the deposition: an increase in the infill density from 30% to 50% leads to an increase in the adhesion strength up to 40%. In summary, the results obtained proved the feasibility of the process and allowed to enucleate directions of future research.

Machining of hybrid structures produced through cold spray technology: A preliminary study

“…Preliminary experimental results and literature findings served as the foundation for the method chosen for the coating production process [14,15]. Several coating tracks were first created by altering the process parameters in a wide range (inlet gas temperature: 150-600 °C, inlet gas pressure: 4-8 bar, stand-off distance (SoD): 10-80 mm).…”

Experimental analysis of cold sprayed precursors for closed-cells aluminum foams

“…During CS, feedstock powder particles (5-50 µm) accelerated to supersonic velocities (300-1200 m/s) by preheated compressed gas passing through a convergent-divergent nozzle, undergo severe plastic deformation upon impact and bond to the substrate [11]. CS, as a "cold" technique, can be used to process thermally sensitive materials [12,13], like the powderbased solid precursors for metal foams. The key idea is spraying the powder mixture on a metallic substrate and then carry out the foaming process in order to obtain the final foamed component.…”

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.…”