Development of Thermal Spray Processes for Depositing Coatings on Thermoplastics

Abstract Thermoplastics combine high freedom of design with economical mass production. Metallic coatings on thermoplastics enable power and signal transmission, shield sensitive parts inside housings can reduce the temperature in critical areas by functioning as a heat sink. The most used technical are polyamides (PA), while described use cases often realized using Cu. Consequently, several studies tried to apply copper PA substrates via thermal spraying; so far, this combination is only feasible an interlayer. In study, new approach metallize spraying based validated state-of-the-art predictions thermoplastics’ material response at relevant temperatures strain rates presented. Using these predictions, velocity wire-arc was selected coating process. Furthermore, process parameters were adapted realize continuous also roughening substrate during deposition. resulting Cu PA6 had sufficiently adhesion for post-treatment grinding. achieved situ application. results indicate that different initial layer deposition further buildup required due low stability PA6.