Organic composite metallization using Low Pressure Cold Spraying

Metallization of polymers using cold spray method, due to low process temperature, is a potential candidate to perform polymers and composites electrically conductive and to improve mechanical properties of their surface (abrasion, corrosion, etc.). To move forward on this path, Low Pressure Cold Sprayed copper coatings on PEEK (Poly-Ether-Ether-Ketone) based composites reinforced by carbon fibers have been investigated. Cold Spraying involving a high erosion on composite materials, due to the solid state and high velocities of impacting particles, a new way has been developed. Based on the elastic behaviors of organic materials, few dozen micrometers of pure PEEK matrix have been added on the surface of the composite to act as an interfacial layer between the composite and the coating. Optimization of the LPCS parameters has then been carried out, using a careful choice of powder size distribution in order to avoid destruction of the substrate, erosion and delamination of the coating.

Consequently, dense thick copper coatings have been obtained and analyzed in terms of microstructure implementing SEM observations. Finally, electric measurements have been performed in order to check the efficient metallization of the composites.