Manufacturing of hybrid thermoplastic-thermoset fiber reinforced composite and metallization by cold spray technique
PARMAR Hetal, RUBINO Felice, POZA Pedro, CARLONE Pierpaolo
download PDFAbstract. Polymer and polymer matrix composites (PMCs) have found applications in aerospace sector. Thermosets (TS) possess higher corrosion resistance, shape retention and durability. Thermoplastics (TP) are easier for remolding in comparison to the former. Surface metallization is one of the recently applied trends for electrical and thermal properties improvement. In different metallization methods, primary restrain is the thermoset surface degradation, whereas thermoplastics have been found to be favorable for metallization. The presented article is part of continuous study aiming the cocuring of thermoset-thermoplastic resin with fibrous reinforcement. The composite manufacturing stage consisted of resin infusion (RI) process route for realizing the composite. Main objective of this stage was the through thickness and linear direction impregnation of thermoset to ensure the sound composite comprising contact between thermoplastic layer as well as fiber reinforcement. Fiber reinforcement combined with the resin infusion auxiliary materials were placed over the thermoplastic material prior to the vacuum bagging stage. Catalyzed thermoset resin impregnation in the vacuum bagged preform was conducted under the cocuring cycle. The composite panel was subsequently metallized via low-pressure cold spraying technique. The coating formation was analyzed with process parameters variation. Qualitatively, coating formation on such hybrid composite substrate was observed. However, the substrate manufacturing was found to have influence on the coating quality. Adhesion pull-off test displayed detachment zone directly in the coating substrate interphase. Presence of voids and less thermoset resin was noticed in the case of coating attempts varying process parameters such as traverse speed and standoff distance. Higher adhesion was noted with lowest selected 1 mm/s traverse speed and 10 mm standoff distance.
Keywords
Polymer Matrix Composites, Cocuring, Resin Infusion, Metallization, Cold Spray
Published online 4/19/2023, 8 pages
Copyright © 2023 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: PARMAR Hetal, RUBINO Felice, POZA Pedro, CARLONE Pierpaolo, Manufacturing of hybrid thermoplastic-thermoset fiber reinforced composite and metallization by cold spray technique, Materials Research Proceedings, Vol. 28, pp 305-312, 2023
DOI: https://doi.org/10.21741/9781644902479-33
The article was published as article 33 of the book Material Forming
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
References
[1] P. Boisse, R. Akkerman, P. Carlone, L. Kärger, S. V. Lomov, J.A. Sherwood, Advances in composite forming through 25 years of ESAFORM, Int. J. Mater. Form. 15 (2022) 39. https://doi.org/10.1007/s12289-022-01682-8
[2] R.M.F. Paulo, F. Rubino, R.A.F. Valente, F. Teixeira-Dias, P. Carlone, Modelling of friction stir welding and its influence on the structural behaviour of aluminium stiffened panels, Thin-Walled Struct. 157 (2020) 107128. https://doi.org/10.1016/j.tws.2020.107128
[3] F. Rubino, M. Pisaturo, A. Senatore, P. Carlone, T.S. Sudarshan, Tribological Characterization of SiC and B4C Manufactured by Plasma Pressure Compaction, J. Mater. Eng. Perform. 26 (2017) 5648-5659. https://doi.org/10.1007/s11665-017-3016-9
[4] F. Rubino, P. Poza, G. Pasquino, P. Carlone, Thermal spray processes in concentrating solar power technology, Metals 11 (2021) 1-30. https://doi.org/10.3390/met11091377
[5] H. Parmar, T. Khan, F. Tucci, R. Umer, P. Carlone, Advanced robotics and additive manufacturing of composites: towards a new era in Industry 4.0, Mater. Manuf. Process. 37 (2021) 483-517. https://doi.org/10.1080/10426914.2020.1866195
[6] F. Tucci, P. Carlone, A.T. Silvestri, H. Parmar, A. Astarita, Dissimilar friction stir lap welding of AA2198-AA6082: Process analysis and joint characterization, CIRP J. Manuf. Sci. Technol. 35 (2021) 753-764. https://doi.org/10.1016/j.cirpj.2021.09.007
[7] F. Tucci, R. Bezerra, F. Rubino, P. Carlone, Multiphase flow simulation in injection pultrusion with variable properties, Mater. Manuf. Process. 35 (2020) 152-162. https://doi.org/10.1080/10426914.2020.1711928
[8] M.R. Rokni, P. Feng, C.A. Widener, S.R. Nutt, Depositing Al-Based Metallic Coatings onto Polymer Substrates by Cold Spray, J. Therm. Spray Technol. 28 (2019) 1699-1708. https://doi.org/10.1007/s11666-019-00911-y
[9] X.L. Zhou, A.F. Chen, J.C. Liu, X.K. Wu, J.S. Zhang, Preparation of metallic coatings on polymer matrix composites by cold spray, Surf. Coatings Technol. 206 (2011) 132-136. https://doi.org/10.1016/j.surfcoat.2011.07.005
[10] M. Grujicic, C.L. Zhao, W.S. DeRosset, D. Helfritch, Adiabatic shear instability based mechanism for particles/substrate bonding in the cold-gas dynamic-spray process, Mater. Des. 25 (2004) 681-688. https://doi.org/10.1016/j.matdes.2004.03.008
[11] H. Parmar, F. Tucci, P. Carlone, T.S. Sudarshan, Metallisation of polymers and polymer matrix composites by cold spray: state of the art and research perspectives, Int. Mater. Rev. 67 (2021) 1-25. https://doi.org/10.1080/09506608.2021.1954805
[12] A. Ganesan, M. Yamada, M. Fukumoto, Cold spray coating deposition mechanism on the thermoplastic and thermosetting polymer substrates, J. Therm. Spray Technol. 22 (2013) 1275-1282. https://doi.org/10.1007/s11666-013-9984-x
[13] A. Ganesan, J. Affi, M. Yamada, M. Fukumoto, Bonding behavior studies of cold sprayed copper coating on the PVC polymer substrate, Surf. Coatings Technol. 207 (2012) 262-269. https://doi.org/10.1016/j.surfcoat.2012.06.086
[14] A. Małachowska, M. Winnicki, M. Stachowicz, M. Korzeniowski, Metallisation of polycarbonates using a low pressure cold spray method, Surf. Eng. 34 (2018) 251-258. https://doi.org/10.1080/02670844.2016.1277843
[15] M. Gardon, A. Latorre, M. Torrell, S. Dosta, J. Fernández, J.M. Guilemany, Cold gas spray titanium coatings onto a biocompatible polymer, Mater. Lett. 106 (2013) 97-99. https://doi.org/10.1016/j.matlet.2013.04.115
[16] H. Che, X. Chu, P. Vo, S. Yue, Metallization of Various Polymers by Cold Spray, J. Therm. Spray Technol. 27 (2018) 169-178. https://doi.org/10.1007/s11666-017-0663-1
[17] V. Gillet, E. Aubignat, S. Costil, B. Courant, C. Langlade, P. Casari, W. Knapp, M.P. Planche, Development of low pressure cold sprayed copper coatings on carbon fiber reinforced polymer (CFRP), Surf. Coatings Technol. 364 (2019) 306-316. https://doi.org/10.1016/j.surfcoat.2019.01.011
[18] F. Rubino, F. Tucci, V. Esperto, A.S. Perna, A. Astarita, P. Carlone, A. Squillace, Metallization of Fiber Reinforced Composite by Surface Functionalization and Cold Spray Deposition, Procedia Manuf. 47 (2020) 1084-1088. https://doi.org/10.1016/j.promfg.2020.04.353
[19] J. Affi, H. Okazaki, M. Yamada, M. Fukumoto, Fabrication of aluminum coating onto CFRP substrate by cold spray, Mater. Trans. 52 (2011) 1759-1763. https://doi.org/10.2320/matertrans.T-M2011807
[20] H. Che, P. Vo, S. Yue, Metallization of carbon fibre reinforced polymers by cold spray, Surf. Coatings Technol. 313 (2017) 236-247. https://doi.org/10.1016/j.surfcoat.2017.01.083
[21] E. Tsiangou, S. Teixeira de Freitas, I. Fernandez Villegas, R. Benedictus, Investigation on energy director-less ultrasonic welding of polyetherimide (PEI)- to epoxy-based composites, Compos. Part B Eng. 173 (2019) 107014. https://doi.org/10.1016/j.compositesb.2019.107014
[22] B. Lestriez, J.P. Chapel, J.F. Gérard, Gradient interphase between reactive epoxy and glassy thermoplastic from dissolution process, reaction kinetics, and phase separation thermodynamics, Macromolecules 34 (2001) 1204-1213. https://doi.org/10.1021/ma0012189
[23] C. Brauner, S. Nakouzi, L. Zweifel, J. Tresch, co-curing behaviour of thermoset composites with a thermoplastic boundary layer for welding purposes, Adv. Comp. Lett. (2020). https://doi.org/10.1177/2633366X20902777
[24] F. Lionetto, M.N. Morillas, S. Pappadà, G. Buccoliero, I. Fernandez Villegas, A. Maffezzoli, Hybrid welding of carbon-fiber reinforced epoxy based composites, Compos. Part A Appl. Sci. Manuf. 104 (2018) 32-40. https://doi.org/10.1016/j.compositesa.2017.10.021
[25] H. Parmar, A. Gambardella, A.S. Perna, A. Viscusi, R. Della Gatta, F. Tucci, A. Astarita, P. Carlone, Manufacturing and metallization of hybrid thermoplastic-thermoset matrix composites, ESAFORM 2021. (2021). https://doi.org/10.25518/esaform21.2727
