The cold gas dynamic spray process developed in the middle of the 80’s reached the industrial stage in development. Even so, many scientific investigations still go on. The nature of the bond between the coating and the substrate is the subject of some controversy. The development of the process will be improved by understanding how the properties of the powder and the mechanical properties of the substrate influence the bonding process. This study analyses the basic dynamics of the process when copper is sprayed. • The one dimensional isentropic model of the gas behaviour in a Laval type nozzle allows evaluating the effect of the gas stagnation pressure P0 and temperature T0 on the impact velocity and temperature of the powder particle. • The analysis of single splats on two substrates (aluminium and steel) shows the influence of the substrate on the deformation of single particles and the influence of the impact speed on the impact shape. • Coatings are made of with powders with a specific size distribution. Two copper powders with a different size distribution are compared based on the deposition efficiency (D.E.) and the mechanical properties of the coating. The mechanical properties tested are the microhardness, the bond strength and the nanohardness. • X-ray diffraction will show that the two powders have an initial very different microstructure. The consequence of this is a different deformation mechanism during the coating build up. • An Auger analysis of the interface has shown the presence of diffusion zone when copper was sprayed on the Al and TA6V substrate. It appears that the size distribution will determine the final impact conditions of the powder. The microstructure of the powder and the oxide content of the powder yield different deformation processes and may explain the differences in D.E. and mechanical properties. The Auger analysis of the interface has yielded diffusion zone that were not expected but some mechanisms under impact loading can explain their presence./ Le procédé de projection thermique à froid a été développé dans le milieu des années 80 et il arrive au stade industriel. Néanmoins, plusieurs développements scientifiques sont encore en cours. La nature du lien entre la poudre et le substrat est toujours l’objet de certaines controverses. Le développement futur du procédé nécessite une bonne compréhension de l’influence de la poudre et des propriétés du substrat sur le mécanisme d’adhérence. Cette étude va mettre en évidence les principaux facteurs influençant la projection de cuivre. • Le modèle unidimensionnel isentropique du gaz parfait dans une buse convergente/ divergente permet de déterminer l’influence de la pression de stagnation et de la température de stagnation sur la vitesse et la température d’impact des particules de poudre. • L’analyse d’impact unique sur les substrats d’acier et d’alliage d’Al (AA2014) montre l’influence du substrat sur la déformation des particules de poudre. La vitesse d’impact a une conséquence importante sur la forme d’une particule projetée sur une surface. . • Les revêtements sont fabriqués à partir de poudre avec une granulométrie donnée. Deux poudres avec une distribution de taille différente sont comparées par leur rendement de déposition et les propriétés mécaniques des revêtements obtenus. Les propriétés mécaniques testées sont la microdureté, l’adhérence et la nanodureté. • La diffraction par rayons-X montre que les deux poudres ont initialement une microstructure très différente. Lors de l’impact, les deux poudres vont se déformer de manière différente et ceci se traduit dans la microstructure. • La spectroscopie Auger montre qu’une zone de diffusion s’est formée à l’interface entre le cuivre et les deux substrats d’Al et de TA6V. La distribution de taille des poudres a une influence considérable sur la vitesse et la température d’impact des particules de poudres mais il apparaît que d’autres facteurs ont aussi énormément d’influence. Le taux d’oxyde dans la poudre a une influence très importante sur le rendement et l’adhérence du dépôt. Les deux poudres projetées ont une microstructure initiale très différente et ceci se traduit par une déformation différente des particules de poudre dans le revêtement.

Carbon fibre reinforced composites are known for their high specific strength-to-weight ratio and are of great interest to the aerospace industry. Incorporating these materials into the fuselage, like in Boeing's 787 "Dreamliner", offers considerable weight reduction which increases flying efficiency, and reduces the cost of flying. In flight, aircraft are often subject to lightning strikes which, in the case of composites, can result in localized melting given the high resistive nature of the material. Aerospace carbon fibre composites often incorporate a metallic mesh or foil within the composite layers to dissipate the electrical charge through the large aircraft. The damage to the aircraft is minimized but not always eliminated. This research aims to elaborate a practical technique to deposit thin layers of conductive material on the surface of aerospace grade composites. Using Cold Gas Dynamic Spray (CGDS), such coatings could be used to repair damaged components. An experimental research approach was used to develop metallic coated composites. Using the CGDS equipment of Centerline (SST-P), specific parameters (such as gas temperature and stagnation pressure) were determined for each type of metallic coating (tin-based & copper-based). The use of bond coats was explored in order to attain the desired coatings. Once optimized, these coatings were evaluated with respect to their corrosive, adhesive, and electrical properties following industry standards.

[pt] A formação de juntas metálicas / poliméricas estáveis é um enorme desafio nas ciências dos materiais. A adesão requer uma interface que é capaz de interagir especificamente com a fase metálica. As poliimidas apresentam grupos amino primários altamente reativos às superfícies metálicas. Os recobrimentos metal/polímero se utilizam principalmente como membranas de separação de gases (permeabilidade e permissividade) e como material de baixa constante dielétrica para dispositivos microeletrônicos. Este trabalho vem fornecer a síntese dos recobrimentos metal/polímero em poliimida e fita kapton, por redução com H2, com posterior compreensão dos mecanismos de quimio-absorção a base de catalisadores da base de paládio, prata, hipoclorito de sodio e da adição de solventes na poliimida PIR 003, que permite a adesão do cobre. Foram utilizados os precursores de cobre em CuSO(4).5H(2)O e do CuCl(2), sintetizados a partir do CuO, para uma posterior redução em atmosfera de H2 e obter cobre métalico no recobrimento, permitindo o desenvolvimento de novas abordagens para metalização de materiais baseados naredução por H2 em polímeros. A utilização de modelos matemáticos permitiu dar uma visualização aproximada do ajuste dos parâmetros na redução do cobre por H2. As medidas do ângulo de contato nas poliimidas funcionalizadas deram uma visualização da influenciada adesão com o cobre e as medidas das caracterizações foram realizadas a fim de mostrar consistência dos resultados dos diferentes tratamentos, entre as quais foram: FTIR, MEV-EDS, TGA, DRX. O presente estudo demostra que com o precursor de CuSO(4).5H(2)O e a funcionalização com o NaClO 50 ml/l na poliimida, apresentou o maior valor de tamanhode cristalito de 61.8 nm e também de maior espessura de recobrimento de 182 micrometros. Finalmente, os testes de adesão para a poliimida PIR 003-Cu com o precursor de CuSO4.5H2O, no recobrimento sem tratamento teve uma força de tração aproximada de 4MPa e no caso do tratamento Sn/Pd (0.1/0.2 g/l) uma média aproximada de 10 MPa. / [en] The formation of stable metallic / polymeric joints is a huge challenge in materialsscience. Adhesion requires an interface that is capable of specifically interacting with themetallic phase. Polyimides have primary amino groups that are highly reactive to metalsurfaces. The coatings of these metal/polymer are mainly used as gas separationmembranes (permeability and permittivity) and as a low dielectric constant material formicroelectronic devices. This work provides the synthesis of metal/polymer coatings inpolyimide and kapton tape, by reduction with H2, with further understanding of the chemoabsorption mechanisms based on catalysts based on palladium, silver, sodium hypochloriteand the addition ofsolvents in the polyimide PIR 003, which allows the adhesion of copper.Copper precursors in CuSO(4).5H2O and CuCl(2), synthesized from CuO, were used forfurther reduction in H2 atmosphere and to obtain metallic copper in the coating, allowingthe development of new approaches for metallization of materials based on H2 reductionin polymers. The use of mathematical models allowed an approximate visualization of theadjustment of the parameters in the reduction of copper by H2. The contact anglemeasurements in the functionalized polyimides gave a visualization of the influence ofadhesion with copper and the characterization measurements were carried out in order toshow consistency of the results of the different treatments, among which were: FTIR,MEV-EDS, TGA, DRX. The present study demonstrates that with the CuSO4.5H2Oprecursor and the functionalization with 50 ml/l sodium hypochlorite in the polyimide, itpresented the largest crystallite size value of 61.8 nm and also the largest coating thicknessof 182 micrometers. Finally, the adhesion tests for the polyimide PIR 003-Cu with the precursor ofCuSO4.5H2O, in the untreated coating had a tensile strength of approximately 4MPa andin the case of the Sn/Pd treatment (0.1/0.2 g/l) a approximate average of 10 MPa.

The cold gas dynamic spray process developed in the middle of the 80’s reached the industrial stage in development. Even so, many scientific investigations still go on. The nature of the bond between the coating and the substrate is the subject of some controversy. The development of the process will be improved by understanding how the properties of the powder and the mechanical properties of the substrate influence the bonding process. This study analyses the basic dynamics of the process when copper is sprayed.<p>• The one dimensional isentropic model of the gas behaviour in a Laval type nozzle allows evaluating the effect of the gas stagnation pressure P0 and temperature T0 on the impact velocity and temperature of the powder particle.<p>• The analysis of single splats on two substrates (aluminium and steel) shows the influence of the substrate on the deformation of single particles and the influence of the impact speed on the impact shape.<p>• Coatings are made of with powders with a specific size distribution. Two copper powders with a different size distribution are compared based on the deposition efficiency (D.E.) and the mechanical properties of the coating. The mechanical properties tested are the microhardness, the bond strength and the nanohardness.<p>• X-ray diffraction will show that the two powders have an initial very different microstructure. The consequence of this is a different deformation mechanism during the coating build up.<p>• An Auger analysis of the interface has shown the presence of diffusion zone when copper was sprayed on the Al and TA6V substrate.<p>It appears that the size distribution will determine the final impact conditions of the powder. The microstructure of the powder and the oxide content of the powder yield different deformation processes and may explain the differences in D.E. and mechanical properties. The Auger analysis of the interface has yielded diffusion zone that were not expected but some mechanisms under impact loading can explain their presence./<p>Le procédé de projection thermique à froid a été développé dans le milieu des années 80 et il arrive au stade industriel. Néanmoins, plusieurs développements scientifiques sont encore en cours. La nature du lien entre la poudre et le substrat est toujours l’objet de certaines controverses. Le développement futur du procédé nécessite une bonne compréhension de l’influence de la poudre et des propriétés du substrat sur le mécanisme d’adhérence. Cette étude va mettre en évidence les principaux facteurs influençant la projection de cuivre.<p>• Le modèle unidimensionnel isentropique du gaz parfait dans une buse convergente/ divergente permet de déterminer l’influence de la pression de stagnation et de la température de stagnation sur la vitesse et la température d’impact des particules de poudre.<p>• L’analyse d’impact unique sur les substrats d’acier et d’alliage d’Al (AA2014) montre l’influence du substrat sur la déformation des particules de poudre. La vitesse d’impact a une conséquence importante sur la forme d’une particule projetée sur une surface. <p>• Les revêtements sont fabriqués à partir de poudre avec une granulométrie donnée. Deux poudres avec une distribution de taille différente sont comparées par leur rendement de déposition et les propriétés mécaniques des revêtements obtenus. Les propriétés mécaniques testées sont la microdureté, l’adhérence et la nanodureté.<p>• La diffraction par rayons-X montre que les deux poudres ont initialement une microstructure très différente. Lors de l’impact, les deux poudres vont se déformer de manière différente et ceci se traduit dans la microstructure.<p>• La spectroscopie Auger montre qu’une zone de diffusion s’est formée à l’interface entre le cuivre et les deux substrats d’Al et de TA6V.<p>La distribution de taille des poudres a une influence considérable sur la vitesse et la température d’impact des particules de poudres mais il apparaît que d’autres facteurs ont aussi énormément d’influence. Le taux d’oxyde dans la poudre a une influence très importante sur le rendement et l’adhérence du dépôt. Les deux poudres projetées ont une microstructure initiale très différente et ceci se traduit par une déformation différente des particules de poudre dans le revêtement.<p> / Doctorat en Sciences de l'ingénieur / info:eu-repo/semantics/nonPublished