Analysis of wear resistance of polymers metallized by cold spray

The production of carbon fibre-reinforced plastics (CFRPs) with complex geometries remains a challenge when using traditional manufacturing techniques, primarily due to the size and format of the reinforcement. The development of 3D printing technologies for composites, such as the Fused Filament Fabrication (FFF) technique, presents a promising solution for manufacturing complex-shaped composites by enabling precise fibre orientation. Despite the undeniable advantages of CFRPs, composite materials exhibit reduced wear resistance and vulnerability to ultraviolet (UV) exposure compared to metals. To address these limitations, surface metallisation using cold spray (CS) technology emerges as a viable alternative. In this context, the aim of this research is to investigate the wear behaviour of 3D FFF-printed composite materials metallised via cold spray. For this purpose, micron-sized aluminium particles were cold sprayed onto composite substrates, and linear scratch tests under various testing conditions were conducted on the samples. Post-test analysis of the wear tracks was performed using confocal and optical microscopy to assess the dimensions and morphology of the wear tracks. The experimental results demonstrated the potential of metallic coatings to enhance the wear performance of additively manufactured composite materials.