Simulation of Depositing Al-Based Metallic Coatings onto Polymer Substrates by Cold Spray in Abaqus

Simulation of Depositing Al-Based Metallic Coatings onto Polymer Substrates by Cold Spray in Abaqus has been investigated in the present tutorial. The  aluminum particles are modeled as three-dimensional solid part in Micro scale. The polyetheretherketone(PEEK) polymer is modeled as a three-dimensional solid part. You can see a figure of the assembled parts below

Polymers are widely used in land and air vehicles because of their low density, ease of forming, and weldability.In the last two decades, the use of polymers to reduce component weight has increased in various industries. However, applications for polymers are limited by intrinsically inferior structural properties relative to metals, including low strength and modulus, poor erosion resis-tance, poor electrical conductivity, susceptibility to UV damage, and low service temperatures.Metal-lization of polymers can be an effective approach to miti-gate these shortcomings and broaden their applications. The objective of the present study is to investigate the feasibility of metallizing polymer substrates using a rela-tively mild process that does not damage or distort the polymer substrate.Presently, few conventional methods are suitable for the surface metallization of polymers.Cold spray (CS) produces uniform metallic deposits by accelerating solid powder particles in a supersonic gas flow to impinge on and deposit onto substrates. Until recently, CS was used primarily to deposit metal onto metallic substrates, primarily for repair of worn or surface-damaged components. Thus, metal-on-metal deposition via CS has been widely studied. However, few studies have been devoted to CS onto polymeric substrates. Substrate erosion reportedly is a key problem with CS onto polymeric substrates, especially with thermoset polymers, which degrade at high temperatures

Proper step, mesh, boundary, and interactions are assigned to the parts. After the simulation, all results such as stress, strain, temperature, contacts, cohesion, and others are available. You can see some figures for the results below