Search

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.

Polymer matrix composites (PMCs) are the most used in aerospace fields due to their special mechanical properties coupled with reduced weight. Metallic structures can be manufactured on the surface of PMCs producing hybrid constructions with intriguing characteristics. The cold spray technology (CS) seems to be the best solution for the manufacturing of metallic coatings on polymer-based substrates. However, the last researches on PMCs metallization through CS were carried out without taking into account a proper manufacturing of the substrates. Therefore, the customized manufacturing of PMCs used as substrates for CS deposition represents a crucial aspect to be considered, the target surface should be designed and manufactured to fit better the CS requirements. In this scenario, the Fused Filament Fabrication method (FFF) is the best solution for tailored composites manufacturing. Therefore, this work aims to develop a novel manufacturing route to produce innovative composite structures by using the FFF technology for the 3D-printed polymer-based substrate and the cold spray technology for the 3D-printed metal deposition. The novelty is that, for the first time, the polymer-based substrates will be designed and manufactured “ad hoc” for the cold spray metallization by using the rapid prototyping 3D-printing process successfully integrated with CS technology.

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.

Cold spray (CS) is a low-temperature process that can be used for the metallization of temperature-sensitive materials, such as polymers or polymer matrix composites, so coupling the lightweight of polymers with the wear resistance, physical properties and hardness of metals. The study of the cold spray of metal particles applied to polymers is still in its early stage and the deposition mechanisms underlying the process are not thoroughly understood yet. Moreover, numerical studies of cold spray of metal-to-polymer are almost completely absent in literature. Therefore, aiming to fulfill this gap of knowledge, the scope of this work is to develop a numerical FE model capable of predicting the impact and the adhesion of a micron size metallic particle onto a polymeric substrate. The results from the model were compared with the experimental outcomes found in literature to establish the effectiveness of the model that was used as a powerful tool to better understand the bonding mechanisms and all the related phenomena ruling the CS process of metal-to-polymer.