Previous results have shown that metallic coatings can be successfully cold sprayed onto polymeric substrates. This paper studies the cold sprayability of various metal powders on different polymeric substrates. Five different substrates were used, including carbon fiber reinforced polymer (CFRP), acrylonitrile butadiene styrene (ABS), polyether ether ketone (PEEK), polyethylenimine (PEI); mild steel was also used as a benchmark substrate. The CFRP used in this work has a thermosetting matrix, and the ABS, PEEK and PEI are all thermoplastic polymers, with different glass transition temperatures as well as a number of distinct mechanical properties. Three metal powders, tin, copper and iron, were cold sprayed with both a low-pressure system and a high-pressure system at various conditions. In general, cold spray on the thermoplastic polymers rendered more positive results than the thermosetting polymers, due to the local thermal softening mechanism in the thermoplastics. Thick copper coatings were successfully deposited on PEEK and PEI. Based on the results, a method is proposed to determine the feasibility and deposition window of cold spraying specific metal powder/polymeric substrate combinations.

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Cold spray has been proven to be a viable method for metallization of polymers and polymer composites, although it has been reported that the mechanism of cold spray on polymeric substrates is different from the mechanism on metallic substrates. In this work, single copper particle impact experiments were performed on polymeric substrates as well as mild steel. Two gas temperatures were selected for each polymer substrate, with one leading to a particle temperature above the glass transition temperature when reaching the substrate and the other below. The particle-substrate interactions on different substrates were analyzed. Based on the results, the mechanism of cold spray on polymeric substrates is discussed and compared to that on metallic substrates.