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Polymer‐Ceramic Composites (PCC) are promising functional materials with a wide range of applications in energy technology, microelectronics and sensor technology, as protective coatings, in wastewater treatment or for biomedical purposes. Unfortunately, ceramics require high‐temperature sintering, while polymers only have a limited thermal stability. Therefore, PCC fabrication is quite complex and requires strict process control. This severely limits the efficiency and economy of the process, and the reproducibility of the desired materials properties. Powder Aerosol Deposition (PAD) is a spray coating process in which ceramic powders are accelerated by a pressure difference using a carrier gas. They are then deposited as nanocrystalline, dense coatings onto different kinds of substrates without the need for additional sintering. Current research focuses on materials obtained from PAD of ceramic powders. Yet there are also examples of mixed polymer and ceramic particles that have been successfully deposited in PAD processes. So far, much of this works does not go beyond the trial‐and‐error stage, so that a general concept for successful deposition of PCCs by PAD is not yet available. This review revisits the fundamentals of the PAD process and its most important process parameters that were studied experimentally and in‐silico. It connects these with recent work on the combination of polymers and ceramics in the PAD process in order to highlight and evaluate the future of this field from a polymer science perspective.This article is protected by copyright. All rights reserved.
Polymer‐Ceramic Composites (PCC) are promising functional materials with a wide range of applications in energy technology, microelectronics and sensor technology, as protective coatings, in wastewater treatment or for biomedical purposes. Unfortunately, ceramics require high‐temperature sintering, while polymers only have a limited thermal stability. Therefore, PCC fabrication is quite complex and requires strict process control. This severely limits the efficiency and economy of the process, and the reproducibility of the desired materials properties. Powder Aerosol Deposition (PAD) is a spray coating process in which ceramic powders are accelerated by a pressure difference using a carrier gas. They are then deposited as nanocrystalline, dense coatings onto different kinds of substrates without the need for additional sintering. Current research focuses on materials obtained from PAD of ceramic powders. Yet there are also examples of mixed polymer and ceramic particles that have been successfully deposited in PAD processes. So far, much of this works does not go beyond the trial‐and‐error stage, so that a general concept for successful deposition of PCCs by PAD is not yet available. This review revisits the fundamentals of the PAD process and its most important process parameters that were studied experimentally and in‐silico. It connects these with recent work on the combination of polymers and ceramics in the PAD process in order to highlight and evaluate the future of this field from a polymer science perspective.This article is protected by copyright. All rights reserved.
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