Date Approved

6-30-2025

Embargo Period

6-30-2025

Document Type

Thesis

Degree Name

M.S. Mechanical Engineering

Department

Mechanical Engineering

College

Henry M. Rowan College of Engineering

Advisor

Francis Haas, Ph.D.

Committee Member 1

Nand K. Singh, Ph.D.

Committee Member 2

Joseph F. Stanzione, III, Ph.D.

Disciplines

Engineering | Mechanical Engineering

Abstract

Metallization of polymer-based composites finds applications in a variety of industries in which addressing challenges such as electrical discharge mitigation or surface erosion can be vital. Cold spray additive manufacturing is emerging as a cutting-edge technology for polymer/composite metallization, offering a transformative approach to achieving desired material enhancements. This study employs finite element analysis (FEA) to evaluate the adhesive “bonding” strength (i.e., extraction force under impulsive dynamic loading) between single 20-micron diameter spherical metal (copper) particles and polymer (polyetheretherketone) substrates under cold spray-relevant impact conditions. Analysis of FEA simulations centers on initial impact processes parameterized by particle impact velocity and particle impact temperature, followed by determination of the extraction force necessary to detach individual metal particles from the substrate. Results reveal that the systems studied reach thermo-mechanical equilibrium within < 10-7 seconds post-impact, with deposition dynamics largely unaffected by the impacting particle temperature, and that a correlation exists between increasing impact velocity (400-700 m/s) and increasing extraction force. Additional simulations show a modest decline in extraction force with increasing temperature. These findings may be useful in optimizing the overall performance of metalized polymer/composites by cold spray and may also offer insights into the thermal-mechanical performance of metallized deposits.

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