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Analysis of the Cold Gas Spraying Process and Determination of Selected Properties of Metallic Coatings on Polymers Aleksandra Malachowska

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Analysis of the Cold Gas Spraying Process and Determination of Selected Properties of Metallic Coatings on Polymers Aleksandra Malachowska Analysis of the cold gas spraying process and determination of selected properties of metallic coatings on polymers Aleksandra Malachowska To cite this version: Aleksandra Malachowska. Analysis of the cold gas spraying process and determination of selected properties of metallic coatings on polymers. Materials. Université de Limoges; Uniwersytet Wro- clawski, 2016. English. NNT : 2016LIMO0012. tel-01741350 HAL Id: tel-01741350 https://tel.archives-ouvertes.fr/tel-01741350 Submitted on 23 Mar 2018 HAL is a multi-disciplinary open access L’archive ouverte pluridisciplinaire HAL, est archive for the deposit and dissemination of sci- destinée au dépôt et à la diffusion de documents entific research documents, whether they are pub- scientifiques de niveau recherche, publiés ou non, lished or not. The documents may come from émanant des établissements d’enseignement et de teaching and research institutions in France or recherche français ou étrangers, des laboratoires abroad, or from public or private research centers. publics ou privés. UNIVERSITE DE LIMOGES ECOLE DOCTORALE SIMMEA Sciences et Ingénierie en Matériaux, Mécanique, Energétique et Aéronautique Faculté des Sciences et Techniques de Limoges Laboratoire Sciences des Procédés Céramiques et Traitements de Surface Thèse N° [-----] Thèse pour obtenir le grade de DOCTEUR DE L’UNIVERSITÉ DE LIMOGES Discipline / Spécialité : Sciences des Matériaux Aleksandra Małachowska Le 22 mars 2016 Analysis of the cold gas spraying process and determination of selected properties of metallic coatings on polymers Thèse dirigée par Andrzej Ambroziak et co-encadrée par Lech Pawłowski Président du jury Wojciech ZORAWSKI Professeur Université de Technologie de Kielce (Pologne) Rapporteurs Thomas LAMPKE Professeur Université de Technologie de Chemnitz (Allemagne) Didier CHICOT Professeur Université Lille 1 Sciences et Technologies (France) Tomasz CHMIELEWSKI Professeur Université de Technologie de Varsovie (Pologne) Membres du jury Andrzej AMBROZIAK Professeur Université de Technologie de Varsovie (Pologne) Lech PAWLOWSKI Professeur Université de Limoges (France) Jerzy NOWACKI Professeur Université de Technologie de Poméranie Occidentale (Pologne) 1 Analysis of the cold gas spraying process and determination of selected properties of metallic coatings on polymers PhD Thesis by Aleksandra Małachowska, MSc, Eng Tutors: Prof. Andrzej Ambroziak and Prof. Lech Pawłowski Additional tutor: dr Tomasz Piwowarczyk Wroclaw University of Technology (Poland) and University of Limoges (France) December 2015 List of contents List of figures ......................................................................................................................... 4 List of tables ......................................................................................................................... 10 List of symbols ..................................................................................................................... 11 1. Thermal spraying methods. ........................................................................................ 14 2. Cold spray method. ..................................................................................................... 16 2.1. High pressure system ............................................................................................ 16 2.2. Low pressure system (LPCS) ................................................................................ 17 3. Coating building ......................................................................................................... 18 3.1. Critical velocity ..................................................................................................... 20 3.2. Bonding formation ................................................................................................ 25 3.3. Numerical simulation ............................................................................................ 27 3.4. Particle and/or substrate preheating ...................................................................... 28 3.5. Particle Oxidation .................................................................................................. 28 3.6. Impacting Angle .................................................................................................... 29 3.7. Loading effect ....................................................................................................... 30 3.8. Substrate effect ...................................................................................................... 31 4. Electrical conductivity of cold sprayed coatings ........................................................ 32 5. Gas thermodynamics in cold spray process ............................................................... 33 5.1. Isentropic flow through the nozzle ........................................................................ 34 5.2. Shock wave ........................................................................................................... 37 5.3. Modelling of gas/particles interactions ................................................................. 38 6. Metallization of polymers – methods ......................................................................... 41 6.1. Electroplating, Electroless Deposition .................................................................. 41 6.2. PVD ....................................................................................................................... 42 6.3. Thermal spraying .................................................................................................. 43 6.4. Cold spray as coating method for polymers .......................................................... 44 7. Aim of the work and range of research ...................................................................... 47 7.1. Genesis of the work ............................................................................................... 47 7.2. Aim of the work .................................................................................................... 48 8. Characterization of used materials ............................................................................. 49 1 8.1. Substrates .............................................................................................................. 49 8.2. Powders ................................................................................................................. 49 9. Experimental methods ................................................................................................ 52 9.1. Coating deposition process – low pressure cold spray stand ................................ 52 9.2. Stereometric measurements .................................................................................. 52 9.3. The adhesion measurements ................................................................................. 53 9.4. Microhardness measurements ............................................................................... 54 9.5. Elastic modulus measurements ............................................................................. 54 9.6. Electrical resistivity measurement ........................................................................ 54 9.7. Temperature-programmed reduction measurement .............................................. 55 9.8. Heat treatment of powder ...................................................................................... 56 9.9. Oxygen content measurements ............................................................................. 57 9.10. Microstructure analysis ..................................................................................... 57 9.11. Granulometry ..................................................................................................... 57 9.12. Coating thickness ............................................................................................... 57 9.13. Coefficient of thermal expansion ...................................................................... 58 9.14. Thermogravimetric analysis .............................................................................. 58 9.15. Temperature measurements ............................................................................... 58 10. Simulations ................................................................................................................. 59 10.1. Particles and gas velocity calculation 1D model ............................................... 59 10.2. Particles and gas velocity calculation 2D model ............................................... 61 10.3. Simulations results ............................................................................................. 61 11. Temperature measurements ........................................................................................ 66 12. Preliminary deposition tests ....................................................................................... 67 12.1. Aluminium coatings .......................................................................................... 69 12.1.1. Aluminum deposition on sandblasted substrate ......................................... 70 12.1.2. Results of aluminum deposition on sandblasted substrate ......................... 72 12.2. Tin coatings ....................................................................................................... 78 12.3. Copper coatings ................................................................................................
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