Metallisation of polymers and polymer matrix composites by cold spray: state of the art and research perspectives

Parmar, Hetal; Tucci, Fausto; Carlone, Pierpaolo; Sudarshan, T. S.

doi:10.1080/09506608.2021.1954805

Cited by 46 publications

(19 citation statements)

References 103 publications

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“…The possibility to obtain high-performance and lightweight structures has attracted a plethora of engineering fields, increasing, in the last few years, the use of PMCs for high-end uses [3]. However, to further expand their fields of application and reduce the issues related to their main drawbacks (such as their poor surface properties and high sensitivity to heat), the metallization of PMCs has been considered as one of the most promising solutions, as studied in the literature [4]. In fact, the surface metallization can enhance the thermal and electrical conductivity of PMCs, improve their erosion behaviour and guarantee lightning protection, which is a crucial aspect to be considered for aircrafts [5,6].…”

Section: Introductionmentioning

confidence: 99%

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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

et al. 2022

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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.

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Section: Introductionmentioning

confidence: 99%

“…Fig 4. Coating tracks made of AlSi10Mg powders produced by CS on both the pure Onyx (3D-O 1 ) and the reinforced (3D-F 1 ) specimens with one layer of matrix on the outermost surfaces…”

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confidence: 99%

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

et al. 2022

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“…As most of the electronics production methods have started using polymers, the metallization process is thus facing challenges such as higher temperature deposition, uniformity, step coverage, throughput, etc. The various metallization techniques revealed so far are: physical vapor deposition, chemical vapor deposition, electrolytic coating, electroforming, thermal spray, cold spray, electroplating, and electroless plating [18][19][20][21]. In most of these processes, electroless deposition (ELD) has been used for metallization as it gives better uniformity, lesser porosity, and good adhesion to non-conducting surfaces [22].…”

Section: Introductionmentioning

confidence: 99%

Detailed Characterization of a Fully Additive Covalent Bonded PCB Manufacturing Process (SBU-CBM Method)

et al. 2022

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To bridge the technology gap between IC-level and board-level fabrications, a fully additive selective metallization has already been demonstrated in the literature. In this article, the surface characterization of each step involved in the fabrication process is outlined with bulk metallization of the surface. This production technique has used polyurethane as epoxy resin and proprietary grafting chemistry to functionalize the surface with covalent bonds on an FR-4 base substrate. The surface was then metalized using an electroless copper (Cu) bath. This sequential growth of layers on top of each other using an actinic laser beam and palladium (Pd) ions to deposit Cu is analyzed. State-of-the-art material characterization techniques were employed to investigate process mechanism at the interfaces. Density functional theory calculations were performed to validate the experimental evidence of covalent bonding of the layers. This manufacturing approach is capable of adding metallic layers in a selective manner to the printed circuit boards at considerably lower temperatures. A complete analysis of the process using bulk deposition of the materials is illustrated in this work.

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“…Polymer metallization using CS has several advantages compared with some counterparts as metal sheet bonding, electroless plating, physical and chemical vapor deposition, and thermal spray techniques. In particular, we can mention [8]: (1) the reduction of processing costs due to high build-up rate, (2) the possibility to achieve higher coating thicknesses, (3) the reduction of metal oxidation that occurs with any thermal process at high temperatures, (4) the reduction of substrate degradation thanks to the lower temperature, and (5) the possibility to avoid size Metals 2021, 11, 1860 2 of 18 limitations of the component as there is no need for an environmental chamber and the spraying device is mounted on a robot, allowing for a full 3D deposition.…”

Section: Introductionmentioning

confidence: 99%

Thermographic Analysis of Composite Metallization through Cold Spray

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Salerno

Bagherifard

et al. 2021

Metals

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Cold Spray is an innovative technology to create coatings through the impact of metallic particles on substrates. Its application to composites’ surfaces is recently attracting the attention of the scientific community thanks to the possibility to functionalize and improve their thermal and wear properties. Within this context, the generation of the first metal-to-composite layer is fundamental. This work presented an experimental investigation of a composite panel, reinforced with glass fibers and coated with aluminum particles. The coating investigation was carried out through active pulsed thermography, analyzing the thermal response of single and double hatches. The thermal outputs were compared with a standard microscopic analysis, with a critical discussion supporting the identification of factors that influence the thermal response to the pulse: (1) layer’s thickness; (2) cold spray coverage; (3) layer compactness; (4) particle-substrate adhesion; (5) particle’s oxidation; and (6) surface roughness.

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Metallisation of polymers and polymer matrix composites by cold spray: state of the art and research perspectives

Cited by 46 publications

References 103 publications

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

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

Detailed Characterization of a Fully Additive Covalent Bonded PCB Manufacturing Process (SBU-CBM Method)

Thermographic Analysis of Composite Metallization through Cold Spray

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