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7409 |
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Development of compatiblizing sublayer for metallizing CFRP structures by cold spray |
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Teng Zhang* / UTBM, France Teng Zhang / Pôle ERCOS, ELLIADD (EA. 4661) - University of Bourgogne Franche Comté, University of Technology of Belfort-Montbéliard, France Essolé Padayodi/ Pôle ERCOS, ELLIADD (EA. 4661) - University of Bourgogne Franche Comté, University of Technology of Belfort-Montbéliard, France Rija Nirina Raoelison/ ICB, UMR 6303 CNRS, University of Bourgogne Franche Comté, University of Technology of Belfort-Montbéliard, France Jean-Claude Sagot/ Pôle ERCOS, ELLIADD (EA. 4661) - University of Bourgogne Franche Comté, University of Technology of Belfort-Montbéliard, France |
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This study aims to develop a metal-based compatibilizing sublayer on a Carbon Fiber-Reinforced Polymer (CFRP) composites to overcome the erosion issue of composites coating using the cold spray deposition technique. The objective is to contribute to the in-situ repair of aircraft structures. Two cases of sublayers, i.e., Al-based sublayer (1126 µm thick) and Cu-based sublayer (547 µm thick), have been prepared and co-cured with the CFRP substrates by contact molding process. Gas-atomized copper powders were deposited on a reference sample of aluminum panel (A-0) and on two functionalized composite substrates (A-1 and C-1) by a high-pressure cold spraying process. The results show that cold spray deposition onto the Al-based sublayer leads to a coating formation whereas the Cu-based sublayer is strongly eroded by the supersonic collision of spherical copper powders. Scanning electronic microscope (SEM) morphologies were used to investigate the deposition mechanisms of cold spraying on various configurations of substrates. It was found that the high deposition efficiency for the case Cu/A-0 was achieved by metallic bonding, evidenced by the significant flattening powders and the agglomeration phenomenon of multiple particles. The copper particles of the case Cu/A-1, encapsulated by the deformed aluminum powders, could anchor to the substrate via mechanical interlocking, whereas only pure localized fracture of epoxy and carbon fiber was observed on the substrate of case Cu/C-1 and thus no particles attached firmly on the substrate. The results demonstrated the feasibility of a sublayer-assisted cold spray process for the thermosetting CFRP composite to achieve a successful deposition of copper powders, which also emphasized the necessity to search an optimal material coupling between sublayer and coatings. |