Date Approved
6-25-2024
Embargo Period
6-25-2025
Document Type
Thesis
Degree Name
Master of Science (M.S.)
Department
Mechanical Engineering
College
Henry M. Rowan College of Engineering
Sponsor
U.S. Army Research Laboratory
Advisor
Behrad Koohbor, Ph.D.
Committee Member 1
Nand Singh, Ph.D.
Committee Member 2
Francis M. Haas, Ph.D.
Keywords
coating enhancements; Cold Spray; composite; metalization; polymer-based; repair
Subject(s)
Polymer coatings; Composite materials
Disciplines
Chemical Engineering | Mechanical Engineering
Abstract
Fiber-reinforced composites have become important structural components in industries such as aerospace and energy due to their high mechanical strength and relatively light structural weight. However, during operation, these materials can be prone to impact damage and disintegration. Effective protection via metalization and repair of composites would, therefore, reduce the cost and time for replacement parts. Polymer-based cold spray, while a relatively new technique, can be utilized to metalize and possibly repair composite materials subjected to impact-induced damage. In this work, studies involving polymers and composite cold spray were performed to enable the process of safeguarding, enhancing, or repairing various composite substrates. Numerical simulations are particularly conducted to illustrate the underlying mechanisms that govern polymer cold spray deposition on composites and how the deposition morphology can vary due to the geometric nonuniformity of the reinforcement phase in a composite substrate. Further simulation studies involving core-shell composite particles (metallic cores with a polymeric shell) were also conducted to achieve coating enhancements to safeguard the composite substrates through the deposition of a metal-rich surface coat and attempt to enhance thermal and electrical conductivity. Complementary experimental studies helped verify the results obtained from simulations and used as guidelines by which polymer cold spray can be used as a repair method for fiber composites.
Recommended Citation
Mennie, Nicholas Beau, "Investigating the Feasibility and Mechanisms of Cold Spray Deposition of Polymer-Based Powders on Fiber-Reinforced Composite Substrates" (2024). Theses and Dissertations. 3256.
https://rdw.rowan.edu/etd/3256
