Metallization of polymers by cold spraying with low melting point powders

Che, Hanqing; Liberati, Andre C.; Chu, Xin; Chen, Meixin; Nobari, Amir Hossein; Vo, Phuong; Yue, Stephen

doi:10.1016/j.surfcoat.2021.127229

Cited by 23 publications

(6 citation statements)

References 26 publications

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“…The local porosities (≈30%; see Figure S2) were observed on the surface, which is primarily attributed to spatial erosion and polymer jetting of the polymer surface due to the high-speed impingement of the Cu particles. 52 Moreover, several discrete polymer regions locally appeared on the as-CS surface, which can be seen from the highlighted spots in Figure 4c. Given the interactions between the particles and the polymer substrate primarily occur in the initial steps of the CS deposition, 48 the localized high-strain rate deformations of the polymer substrate encapsulate the embedded particles.…”

Section: ■ Results and Discussionmentioning

confidence: 92%

“…Figure c presents the SEM analysis of the as-CS ABS surface. The local porosities (≈30%; see Figure S2) were observed on the surface, which is primarily attributed to spatial erosion and polymer jetting of the polymer surface due to the high-speed impingement of the Cu particles . Moreover, several discrete polymer regions locally appeared on the as-CS surface, which can be seen from the highlighted spots in Figure c.…”

Section: Results and Discussionmentioning

confidence: 94%

“…22 Despite these intrinsic advantages, it remains challenging to achieve electrically conductive metallization through the solely cold spraying of hard metal particles such as copper (Cu) on thermoplastic substrates for polymer electronics applications. The reasons are (i) poor erosion resistance of polymers 23 and (ii) the polymer jetting phenomenon. 24 To elaborate, the high-speed bombardment of particles leads to erosions as well as localized melting of the polymer (i.e., jetting) that acts as a separator among the as-deposited particles by encapsulating them.…”

Section: ■ Introductionmentioning

confidence: 99%

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Selective Surface Metallization of 3D-Printed Polymers by Cold-Spray-Assisted Electroless Deposition

Akin,

Nath,

Jun

2023

ACS Appl. Electron. Mater.

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Selective surface metallization of insulating polymers is of particular interest in smart films, energy harvesting, and sensing applications. However, traditional polymer metallization techniques face challenges due to the need for environmentally hazardous pretreatment (e.g., strong acid etching) and costintensive palladium seeding processes, thereby limiting the largescale deployment of metallized polymers. With the advent of rapid prototyping, metallization on additively manufactured polymers drew attention in a variety of technological applications, as it enables the fabrication of low-cost electronic devices. In the current work, we deploy and evaluate a hybrid additive metallization route that can enable the fabrication of functional selective metallization on 3D-printed polymers in a rapid and eco-friendly methodology with improved electrical conductivity. The metallization route sequentially comprises (1) material extrusion 3D printing, (2) cold spray metallization, and (3) electroless deposition. The resulting metal (copper) layers on the polymer surfaces are characterized in terms of the microstructure, surface chemistry, wettability, and electrical conductivity. Notably, selective metallization with promising electrical conductivity (i.e., 6.47 × 10 6 S m −1 for ABS and 5.27 × 10 6 S m −1 for PLA parts) is achieved on both linear and curvilinear polymer surfaces. Moreover, strong adhesion between the metallized layer and the 3Dprinted structures was confirmed by adhesion tests. Detailed evaluation of the proposed hybrid metallization route unlocks great potential to advance the field of conductive surface metallization on 3D-printed polymers.

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Section: ■ Results and Discussionmentioning

confidence: 92%

Section: Results and Discussionmentioning

confidence: 94%

Section: ■ Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Selective Surface Metallization of 3D-Printed Polymers by Cold-Spray-Assisted Electroless Deposition

Akin,

Nath,

Jun

2023

ACS Appl. Electron. Mater.

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“…Table 2 provides various investigations and their observations. In the information provided below, the term deposition efficiency (DE) is by definition the substrate weight change divided by the overall weight of powder sprayed for the duration of which the spraying gun is actually over the sample [74]. Giraud et al investigated the effects of carrier gas temperatures and pressure upon cold spraying Al powders on PA66 substrate [4].…”

Section: Influence Of Processing Parametersmentioning

confidence: 99%

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

Parmar

Tucci

Carlone

et al. 2021

International Materials Reviews

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Surface treatments on polymer-based materials are frequently used to enhance mechanical and physical properties. Cold spray is a metallisation technique that provides a viable solution to overcome the main drawbacks of conventional thermal spray processing techniques related to surface degradation at high temperatures. This review provides a critical overview on the metallisation of polymers and polymer matrix composites using cold spray. It offers an informative read on different approaches, bonding mechanisms, spraying procedures and parameters that influence the deposition efficiency, and the features of the coating. The future scope section broadly highlights potentially relevant areas for further developments using the method for metallising polymer-based substrates.

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“…Some commonly used techniques include physical vapor deposition (PVD), chemical vapor deposition (CVD), electrochemical deposition, and thermal spray. Che et al 9 and Liberati et al 10 highlight that, in addition to the technique itself, other factors must be considered in the metallization process, such as the materials and environmental impacts. For example, through electrodeposition, Zhang et al 11 obtained silver, copper, and nickel (Ag‐Cu‐Ni) films on ABS and analyzed both the oxidation resistance of the sample and the film‐substrate adhesion, relating them to the presence of Ni and the interlayers of Ag and Cu, respectively.…”

Section: Introductionmentioning

confidence: 99%

Sputtering: An eco‐friendly technique to obtain polymer‐metal hybrids

Moretti,

Recco,

Becker

2023

J of Applied Polymer Sci

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Among the methods commonly used to obtain polymer‐metal hybrids, sputtering has stood out for its ability to deposit thin films at room temperature. Another highlight is that it does not produce toxic gases or residues to the environment, making it an eco‐friendly solution. This work aimed to produce and characterize stainless steel (SS) films on acrylonitrile‐butadiene‐styrene (ABS) polymer using a magnetron sputtering with a direct current source. The ABS‐SS surface and interface, the ABS thermal behavior, and the film‐substrate adhesion quality were analyzed. The characterization techniques were atomic force microscopy and scanning electron microscopy to reveal the surface, x‐ray fluorescence spectroscopy to determine the chemical composition, and transmission electron microscopy to determine the phases on the ABS‐SS interface. The samples' thermal behavior was analyzed through thermogravimetry and differential scanning calorimetry. Method B from the ASTM D3359 standard qualitatively evaluated the film‐substrate adhesion. The characterizations showed that the ABS did not degrade significantly during SS deposition and that the sample had acceptable film‐substrate adhesion quality, making the technique and deposition parameters suitable for the obtention of this hybrid material.

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Metallization of polymers by cold spraying with low melting point powders

Cited by 23 publications

References 26 publications

Selective Surface Metallization of 3D-Printed Polymers by Cold-Spray-Assisted Electroless Deposition

Selective Surface Metallization of 3D-Printed Polymers by Cold-Spray-Assisted Electroless Deposition

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

Sputtering: An eco‐friendly technique to obtain polymer‐metal hybrids

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