Etude expérimentale et numérique de la conductivité de revêtements composites métal-polymère déposés par projection dynamique par gaz froid sur substrat composite à matrice organique

Abstract : The Cold Spray process allows to manufacture metallic coatings onto Carbon Fiber-Reinforced Composite (CFRP). This process relies on the spraying of high-velocity powder particles to result in high deformation and build up to form a dense coating. However, forming a coating made of copper particles onto a substrate containing carbon fibers was achieved out only by mixing metallic powder with a polymer powder. Although the polymer allow to build up the coating onto CFRP, it is highly electrically insulating. It would therefore decrease the electrical conductivity of the coating drastically. Investigations were carried out on the influence of the coatings microstructure on electrical conductivity. Various copper powders, with different morphologies, granulometry and oxygen contents were mixed with PEEK powder, i.e. a thermoplastic polymer. Cold spray of these powders leads to homogeneous coatings onto CFRP. The characteristics of these coatings were studied as a function of the influence of powder characteristics and spraying parameters. The deformation of the PEEK was also investigated as it governed the build up of the coating. Mechanical testing of PEEK samples and in-situ spraying measurements were performed to feed impact simulations. Then, simulated and experimental impact morphologies of copper particles onto PEEK were compared. The PEEK behavior under impact also prevented sound contacts between copper particles, which decreased the coatings electrical conductivity significantly. A morphological model of the microstructure of the coating was developed to reproduce microstructures in 3D numerically. It allows to investigate numerically the influence of the copper phase morphology on coating conductivity. This conductivity was measured experimentally for various starting copper powders. A carefully selected blend of copper and PEEK powders and optimized spraying parameters lead to homogeneous coatings onto CFRP with an acceptable electrical conductivity but still below bulk copper conductivity.
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Vincent Bortolussi. Etude expérimentale et numérique de la conductivité de revêtements composites métal-polymère déposés par projection dynamique par gaz froid sur substrat composite à matrice organique. Matériaux. PSL Research University, 2016. Français. ⟨NNT : 2016PSLEM075⟩. ⟨tel-01712448⟩

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