Adhesion Enhancement of a Metallic Al Coating Fabricated by Detonation Gun Spray on a Modified Polymer Matrix Composite
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Adhesion Enhancement of a Metallic Al Coating Fabricated by Detonation Gun Spray on a Modified Polymer Matrix Composite Yongjing Cui1,2 • Mengqiu Guo1 • Changliang Wang1 • Zhihui Tang1
Submitted: 7 March 2019 / in revised form: 31 August 2019 Ó ASM International 2019
Abstract Detonation gun (D-gun) spraying technology was utilized to fabricate Al coatings on modified polymer matrix composite substrates. Prior to the application of the D-gun-sprayed Al coating, an epoxy-Al-mixed layer was directly sprayed onto the laminates surface and cured without sandblasting. The properties of the coatings were characterized utilizing scanning electron microscope, transmission electron microscope, x-ray diffraction, and mechanical testing. The results indicate that well-bonded, polycrystalline Al coatings were fabricated by D-gun spraying technique. The addition of the mixed epoxy-Almixed transition layer significantly improved the bond strength of the D-gun-sprayed Al coating on the carbon fiber-reinforced polymer (CFRP) substrate from 8.6 to 21.5 MPa. Moreover, carbon fiber damage was rarely detected in the precured CFRP coupons, indicating less mechanical property degradation of the modified CFRP than that of the traditional sandblast pretreatment. Keywords adhesive strength Al coating D-gun spraying PMC
& Yongjing Cui [email protected] 1
AECC Beijing Institute of Aeronautical Materials, Beijing 100095, China
2
Science and Technology on Thermostructural Composite Materials Laboratory, Northwestern Polytechnical University, Xi’an 710072, Shaanxi, China
Introduction Polymer matrix composite (PMC) materials have been extensively utilized as the most promising alternative to traditional metallic parts for airframes and aeroengines since they have a relatively low density, high specific strength and modulus, a small linear expansion coefficient, and unique electromagnetic properties compared with those of metallic materials (Ref 1, 2). Nevertheless, the drawback of low thermal and electrical conductivities has hindered their application as lightweight alternatives to metals, especially regarding the replacement of aluminum alloy airfoils, where lightning protection and high conductivity are necessary. Indeed, metallization is an effective and commonly used method to effectively improve the surface conductivity of PMC materials (Ref 3, 4). Several techniques, such as plating (Ref 5), magnetron sputtering (Ref 6), cold spraying (Ref 4), and thermal spraying (Ref 7-9), have been utilized for PMC metallization and surface protection. Thermal spraying technologies, as well as cold spraying, have attracted increasing attention for larger surface area metallization due to their low cost and high degree of automation capability. Zn, Al, Cu, Ti, and Cu/Zn/Sn-mixed metallic coatings have been reported to be fabricated on the polymer-based composites by flame spraying, arc spraying, atmospheric plasma spraying, and cold spraying (Ref 10-12). However, thermal spraying of metallic coatings on polymer-based composi
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