Carbon fiber-reinforced plastic (CFRP) has a great potential application in aircraft fuselage due to its light weight, high specific stiffness and high specific strength. It is crucial to coat the CFRP surface with an electrically conductive material to avoid the damage from lightning strike. Cold spray process has been developed for metallic coating technique. In this study, aluminum coating was fabricated onto the CFRP substrate using interlayer was investigated. It was difficult to fabricate cold-sprayed aluminum coating directly on the CFRP substrate. Though smaller size aluminum particles could be deposited on the CFRP substrate, but the coating was peeled off when the thickness was around 30 mm. On the other hand, it was possible to deposit aluminum coating on the CFRP substrate by plasma spray process. Our proposed structure is using a thin plasma-sprayed aluminum interlayer on the CFRP substrate before doing the cold spray. The interlayer with larger contact area could retain on the substrate and able to facilitate the deformation of the next incoming cold-sprayed particles to build a thick coating. The volume resistivity of cold spray coating is lower than the plasma sprayed aluminum coating because of high process gas temperature in the latter case enhances the oxidation of sprayed particle. Therefore, lower process gas temperature should be used to fabricate lower volume resistivity coating on cold spray.

Carbon fiber reinfbrced plastics ( CFRP ) has a great potential apPlication in aircraft fUse 互 age due to the孟 r high speci 厳c sti臨 ess and specl 避c strength ． It is crucial to coauhe CFRP surface with a high conductivity metal in order to reduce the effect of lightning strike on the aircraft ． Thermal spray process can be used to produce coating on CFRP subs 症 ate， However ， the volume resistivity of thermal sprayed coating is higher than that of its buIk metal ． Moreover ， the coating obtained is porous and has high oxidation conten し The cold spray process is an attractive method to make a dense and tight coating without any detrimental effects acquired 丘om the high temperature process ． On this study ， aluminium coating was successfully cold sprayed onto CFRP substrate with interlayer coating processed by plasma spray ． The volume resistivlty of coadng was significantly lower than coating produced by plasma spray process