Date Approved

6-24-2024

Embargo Period

6-25-2024

Document Type

Thesis

Degree Name

Master of Science (M.S.)

Department

Mechanical Engineering

College

Henry M. Rowan College of Engineering

Advisor

Francis M. Haas, Ph.D.

Committee Member 1

Joseph F. Stanzione, III, Ph.D.

Committee Member 2

Behrad Koohbor, Ph.D.

Keywords

cold spray technology, polymer coatings

Subject(s)

Coating processes; Additive manufacturing

Disciplines

Mechanical Engineering

Abstract

The purpose of this thesis is to explore and expand the capabilities of polymer-on-polymer cold spray demonstrated herein using polyamide 6 (PA6)-based powder and substrates. Experiments were conducted using three different cold spray systems described in this work, permitting more in-depth examination of process response to different cold spray process control parameters, such as nominal system pressure and temperature. Two specific responses of interest were the deposition window (DW) and deposition efficiency (DE) of PA6. The DW was determined by performing several sprays at different calculated particle impact velocities and temperatures. The composite result from these experiments was identification of a large DW in which the role of the particle impact temperature was noticeable enough that, in addition to critical velocity, present results suggest that a critical particle temperature should be considered when determining DWs for polymer powder spraying. Additionally, the combined DW results from all three systems show that particle impact velocity and particle impact temperature alone may be too simple to describe clear regions of deposition. The DE was determined by using a single low-pressure, downstream injection cold spray system. Under favorable conditions, a DE of ∼67% was measured for PA6, roughly seven times higher than the highest DE previously described in the literature for polymer-on-polymer cold spray.

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