Metallic Coating for Carbon Fiber Reinforced Polymer Matrix Composite Substrate

Authors: Amine Rezzoug, Said Abdi, Nadjet Bouhelal, Ismail Daoud

Abstract:

This paper investigates the application of metallic coatings on high fiber volume fraction carbon/epoxy polymer matrix composites. For the grip of the metallic layer, a method of modifying the surface of the composite by introducing a mixture of copper and steel powder (filler powders) which can reduce the impact of thermal spray particles. The powder was introduced to the surface at the time of the forming. Arc spray was used to project the zinc coating layer. The substrate was grit blasted to avoid poor adherence. The porosity, microstructure, and morphology of layers are characterized by optical microscopy, SEM and image analysis. The samples were studied also in terms of hardness and erosion resistance. This investigation did not reveal any visible evidence damage to the substrates. The hardness of zinc layer was about 25.94 MPa and the porosity was around (∼6.70%). The erosion test showed that the zinc coating improves the resistance to erosion. Based on the results obtained, we can conclude that thermal spraying allows the production of protective coating on PMC. Zinc coating has been identified as a compatible material with the substrate. The filler powders layer protects the substrate from the impact of hot particles and allows avoiding the rupture of brittle carbon fibers.

Keywords: Arc spray, coating, composite, erosion.

Digital Object Identifier (DOI): doi.org/10.5281/zenodo.1338738

References:

[1] T. J. Reinhart, Engineered Materials Handbook Volume 1: Composites, ASM International, Metals Park, OH USA, 1987.pp. 39-50
[2] M. Ivosevic, R. Knight, S.R. Kalidindi, G.R. Palmese, J.K. Sutter,’’ Solid particle erosion resistance of thermally sprayed functionally graded coatings for polymer matrix composites’’ J. Therm. Spray Technol. 14 (2005) 45.
[3] A. Liu, M. Guo, J. Gao, M. Zhao, ‘’Arc sprayed erosion-resistant coating for carbon fiber reinforced polymer matrix composite substrates’’Surf. Coat. Technol. 201 (2006) 2696.
[4] F. Robitaille , M. Yandouzi , S. Hind , B. Jodoin, ‘’Metallic coating of aerospace carbon/epoxy composites by the pulsed gas dynamic spraying process’’, Surface & Coatings Technology, (2009).
[5] I. Grimberg, K. Soifer, B. Bouaifi, U. Draugelates, B.Z. Weiss, Tungsten Carbide Coatings Deposited By High-Velocity Oxy-Fuel Spraying On A Metallized Polymeric Substrate, Surface And Coatings Technology 90 (1997) Page 82-90
[6] K.Miyoshi, J .K. Sutter, R. A. Horan, S. K. Naik, and R. J. Cupp’’Assessment of Erosion Resistance of Coated Polymer Matrix Composites for Propulsion Applications’’ NASA/TM—2004-212911
[7] I.Grimberg, K. Soife, B.Bouaifi, U. Draugelates, B. Z. Weiss’’ Tungsten carbide coatings deposited by high-velocity oxy-fuel spraying on a metallized polymeric substrate’’ Surface and Coatings Technology,(1997)
[8] M. Ivosevic, R. Knight, S. R. Kalidindi, G. R. Palmese, J. K. Sutter,’’ Adhesive/cohesive properties of thermally sprayed functionally graded coatings for polymer matrix composites’’ Journal of Thermal Spray Technology,(2005) page 45-51
[9] R. Knight, M. Ivosevic, S. Kalinidi, G. Palmese,’’ Optimal Substrate Preheating Model for Thermal Spray Deposition of Thermosets Onto Polymer Matrix Composites’’ International Thermal Spray Conference and Exposition,(2005)
[10] R.Wang, D.Song, W.Liu, X.He,’’E ffect of arc spraying power on the microstructure and mechanical properties of Zn–Al coating deposited onto carbon fiber reinforced epoxy composites’’ Applied Surface Science 257 (2010) 203-209
[11] F. Alonso, I. Fagoaga, P. Oregui,’’ Erosion protection of carbon—epoxy composites by plasma-sprayed coatings’’ Surface and Coatings Technology,(1991), page 482-488
[12] R. Lupoi, W. O'Neill,’’ Deposition of metallic coatings on polymer surfaces using cold spray’’ Surface and Coatings Technology,(2010),page 2167-2173
[13] Engineered Materials Handbook Volume 5: Surface Engineering, ASM International, Catherine M. Cotell, James A. Sprague, and Fred A. Smidt, Jr, 1994
[14] American Society for Testing and Materials. Standard test method for vickers hardness of metallic materials. ASTM E92-82 e2; 2003.
[15] H. K. Pulker, W. Haag, M. Buhler, E. Moll, Proc. 5th Int. Conf. on Ion Plasma Assisted Techniques (Munich), CEP Consultants Ltd., Edinburgh,(1985), pp. 209-306.
[16] ASTM, G76 – 13 Standard Test Method forConducting Erosion Tests by Solid Particle Impingement Using Gas Jets
[17] Standard ASTM E1920-03, Guide for Metallographic Preparation of ThermalSprayed Coating
[18] Standard ASTM E2109. Standard test methods for determining area percentageporosity in thermal sprayed coatings.
[19] Bores Cylinder. "Thermal Spray & Surface Engineering." Advanced Materials & Processes 39 (2007): 1.