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Thermal spraying technology for applying metal coatings on polymer substrate

Country of Origin: Belarus
Reference Number: TOBY20180613001
Publication Date: 14 June 2018

Summary

Belarus research institute developed a technique which allows metallizing of thin polymer substrates by thermal spraying. The resulting adhesion tensile strength is 1.5-2 times higher than by arc spraying and metal plating correspondingly. It can be used to protect unmanned vehicles from electromagnetic (EM) pulses or provide EM interference shielding for electronic equipment. The institute seeks cooperation with industrial partner for commercial agreement with technical assistance.

Description

Wide usage of drones and unmanned vehicles requires their protection from electromagnetic (EM) pulse attacks. The calculations of shielding efficiency of EM screens from various materials show that in the frequency range of electromagnetic radiation from 60 Hz to 1 kHz, the screen thickness should be more than 1 mm.

At present the vacuum deposition process is used for metallizing of polymers. The main drawbacks of vacuum technologies are the limited size of polymer components and the small thickness of the coating (5-20 μm), which provides effective shielding only for frequencies above 1 MHz.

To form thicker metal coatings the research institute from Belarus offers thermal spraying technique - hypersonic metallizing. In hypersonic metallizing the feedstock (metal wires) is melted by the electric arc and the molten metal is sprayed by a jet of propane-air mixture combustion products. The technique requires abrasive jet pretreatment of the surface, applying the underlayer (if necessary) and then spraying the functional coating of a required thickness.

Characteristics of hypersonic metallizing:
* dynamic pressure: 23.5e4 kg/(m*s2)
* particle velocity: up to 500 m/s
* particle size: 5-25 μm
* feedstock: steel, copper, aluminium, zinc, etc. or any combination of two.

Parameters of coatings on polymer substrate:
* thickness: from 100 μm up to 3 mm
* adhesion tensile strength: more than 2.5 MPa
* high corrosion resistance
* density of aluminium, zinc, copper: almost 100%.

Hypersonic metallizing can be used to form protective coatings on polymer bodies of unmanned vehicles against electromagnetic pulses or to provide electromagnetic interference shielding for electronic equipment.

The institute seeks cooperation with industrial partner for commercial agreement with technical assistance. Desired is a contract for an adaptation of hypersonic metallizing to the specific manufacturing process of the buyer.
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Advantages and Innovations

Main advantages are:
* adhesion tensile strength is 1.5-2 times higher than by arc spraying and metal plating correspondingly
* high density coating with thickness up to 3 mm.

Stage Of Development

Available for demonstration

Requested partner

Industrial partner designing unmanned vehicles, communication devices or electronic equipment which require protection from electromagnetic pulse attacks for buying the technology under commercial agreement with technical assistance.

Cooperation offer ist closed for requests