Numerical Modeling of Bond Formation in Polymer Surface Metallization Using Cold Spray

Abstract Surface metallization of polymeric materials using cold spray technology has gained increasing attention in the past decade. Experimental studies have evidenced multiple challenges this process regarding continuity and homogeneity metallic deposits on polymer substrates. Modeling simulation tools could be very helpful to assess efficiency different strategies suggested for improved deposition at a considerably reduced cost; nevertheless, efforts use numerical modeling sector been less successful. Here, we develop detailed finite element model metal particles substrates shed light underlying mechanisms. The results are compared with literature experiments establish effectiveness proposed model. developed is able capture key phenomena involved mechanism particularly particle substrate mechanical interlocking local melting. It shown that velocity threshold value should exceeded achieve an effective interlocking. substate thermal domain melting as well effects size deformation anchorage discussed.