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Metallization of Porous Polyethylene Using a Wire-Arc Spray Process for Heat Transfer Applications.

S Devaraj1, A McDonald2, S Chandra1

  • 1Department of Mechanical and Industrial Engineering, University of Toronto, Toronto, ON M5S 3G8 Canada.

Journal of Thermal Spray Technology
|April 16, 2024
PubMed
Summary
This summary is machine-generated.

Metallizing porous polyethylene with copper, aluminum, and zinc using twin wire-arc spraying proved successful. The resulting metallic coatings exhibited strong adhesion, enabling lightweight composite materials for thermal management.

Keywords:
polymer metallizationporous substratesplat impactwire-arc spraying

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Area of Science:

  • Materials Science
  • Polymer Science
  • Surface Engineering

Background:

  • Metallizing low melting point polymers like polyethylene (PE) via thermal spraying is challenging.
  • Traditional methods struggle with PE's softness and low thermal stability.

Purpose of the Study:

  • To investigate the feasibility of metallizing porous polyethylene using twin wire-arc spraying.
  • To evaluate the adhesion, morphology, and electrical properties of metallic coatings on porous PE.

Main Methods:

  • Twin wire-arc spraying of copper (Cu), aluminum (Al), and zinc (Zn) onto 3 mm thick porous polyethylene substrates.
  • Scanning electron microscopy (SEM) for surface and cross-section analysis.
  • Adhesion strength and electrical resistivity testing.

Main Results:

  • Successful deposition of ~400 µm thick metallic coatings (Cu, Al, Zn) without surface preparation.
  • Observed differences in metal splat morphology and bonding mechanisms on porous vs. non-porous substrates.
  • Coating bond strength exceeded the fracture strength of the porous polyethylene substrate.

Conclusions:

  • Porosity in polyethylene substrates significantly enhances metallic coating adhesion.
  • Twin wire-arc spraying is a viable method for metallizing porous polyethylene.
  • This technique enables the creation of lightweight composite materials for thermal management applications.