Cold spray metallic coating and methods
AssigneeThe Boeing Company
InventorsEric A. Bruton, Stephen P. Gaydos
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Abstract
The present disclosure relates to a cold spray metal process for imparting electromagnetic interference (EMI) resistance or lightning protection to the surface of a polymer, and a polymer with surface EMI resistance, or lightning protection, articles coated therefrom, and methods of reducing or eliminating electrochemical interactions between the metallic coating and components of the polymer.
Claims20
A method of reducing or eliminating at least one electrochemical interaction between a metallic coating and a polymer in a formed article, the method comprising:
- introducing particles of a metal powder or metal alloy powder or a mixture of the metal powder and the metal alloy powder to a gas stream;
- directing the gas stream toward an electrochemical insulating layer present on a surface of a polymer, wherein the gas stream has a temperature and a pressure adjusted to prevent thermal softening or ablation of the surface of the electrochemical insulating layer;
- forming a metallic coating on at least a portion of the electrochemical insulating layer;
- reducing or eliminating electrochemical interaction between the metallic coating and the polymer;
- and
- introducing an additional metallic layer comprising niobium on at least a portion of the metallic coating using a cold spray process;
- wherein the metal powder or the metal alloy powder comprises copper;
- and
- wherein the metallic coating imparts electrical EMI resistance or lightning protection to the formed article.
A method of reducing or eliminating at least one electrochemical interaction between a metallic coating and a polymer in a formed article, the method comprising:
- introducing particles of a metal powder or metal alloy powder or a mixture of the metal powder and the metal alloy powder to a gas stream;
- directing the gas stream toward an electrochemical insulating layer present on a surface of a polymer, wherein the gas stream has a temperature and a pressure adjusted to prevent thermal softening or ablation of the surface of the electrochemical insulating layer;
- forming a metallic coating on at least a portion of the electrochemical insulating layer;
- and
- reducing or eliminating electrochemical interaction between the metallic coating and the polymer;
- and
- introducing an additional metallic layer comprising niobium on at least a portion of the metallic coating using a cold spray process;
- wherein the metal powder or the metal alloy powder comprise aluminum, copper, gold, silver, or a combination thereof;
- wherein the metallic coating has a surface roughness configured to be coatable or paintable;
- and
- wherein the metallic coating imparts electrical EMI resistance or lightning protection to the formed article.
A method of reducing or eliminating at least one electrochemical interaction between a metallic coating and a polymer in a formed article, the method comprising:
- introducing particles of a metal alloy powder to a gas stream;
- directing the gas stream toward an electrochemical insulating layer present on a surface of a polymer, wherein the gas stream has a temperature and a pressure adjusted to prevent thermal softening or ablation of the surface of the electrochemical insulating layer;
- forming a metallic coating on at least a portion of the electrochemical insulating layer;
- reducing or eliminating electrochemical interaction between the metallic coating and the polymer;
- and
- further comprising introducing an additional metallic layer comprising a cold sprayed metal comprising niobium on at least a portion of the metallic coating,
- wherein the metal alloy powder comprises aluminum, copper, gold, silver, or a combination thereof;
- wherein the metallic coating has a surface roughness configured to be coatable or paintable;
- and
- wherein the metallic coating imparts electrical EMI resistance or lightning protection to the formed article.
Dependencies are inferred from the claim text.