Metallization of carbon fiber reinforced polymer composite by cold spray and lay-up molding processes

• Possibility of covering a CFRP with a metallic layer using cold spray and Lay-up molding processes
• CFRP was built on the mold over the CS coating and removed from the mold along with the coating.
• Adhesion strength of 2.6 ± 0.8 MPa and electrical resistivity of 3.6 x 10−8 Ωm ± 0.3 x 10−8 Ωm were obtained.

With their high specific strength-to-weight ratio, carbon fiber reinforced composites are state of the art materials used in the aerospace industry, including fuselage parts. Studies have shown that it is complicated and costly to coat carbon fiber based composites using conventional thermal spray processes. For the purpose of producing metallic coated carbon fiber based composites, a new innovative technique which combines Cold Spray and lay-up molding of composites is envisioned. This paper presents a detailed description of the experimental approach developed to produce metallic coated carbon fiber reinforced composites and demonstrates the manufacturability of such components. Obtainment of a low resistivity metallized composite and production of an easily removable metallic layer from the mold during lay-up molding, and preservation of the mold integrity are essential for the production of such materials. The results produced show that it is possible to produce metallized composites of various shapes that are easily removable from the mold and have low porosity and high conductivity.