Recent Advances in Spray Coating Technology for Carbon Fiber-Reinforced Polymer Composites: From Material Selection...

Area of Science:

• Materials Science
• Surface Engineering
• Polymer Composites

Background:

• Spray coating is a promising surface modification technique for advanced materials.
• Carbon fiber-reinforced polymer (CFRP) composites require precise fabrication for high-end applications.
• Understanding the process-structure-performance relationship is crucial for optimizing composite properties.

Purpose of the Study:

• To systematically review recent advancements in spray-based fabrication of CFRP composites.
• To elucidate the intrinsic relationships between spray coating processes, resulting structures, and composite performance.
• To provide a framework for mechanical, thermal, and electromagnetic enhancement in spray-coated CFRPs.

Main Methods:

• Detailed elaboration of spray coating design principles: fiber pretreatment, material selection, parameter control, and techniques.
• Introduction to advanced characterization of spray-formed microstructures.
• Discussion of intrinsic mechanisms for performance enhancement.

Main Results:

• Spray coating allows for precise interface engineering and multidimensional network construction in CFRPs.
• Optimized microstructures enhance stress, heat, and charge transport within the composite.
• Established frameworks for mechanical reinforcement, thermal management, and electromagnetic integration.

Conclusions:

• Spray coating technology offers significant potential for aerospace, marine, and electronic applications.
• Future research should focus on process standardization, advanced characterization, and performance design.
• This review provides guidance for rational design, process optimization, and industrial adoption of spray coating for CFRPs.