Abstract
Titanium powders were cold sprayed onto polyetheretherketone (PEEK) to investigate the effects of interface microstructure on bonding. Process guidelines to achieve adherent metallic deposits via cold spray onto thermoplastics are scarce, and mechanisms for metal adhesion onto thermoplastic substrates are unclear. The formation of a transition layer where deposition changes from metal-on-polymer to metal-on-metal deposition can promote adhesion but requires a clearer understanding. The microstructural features of such transition layers provide insights into mechanisms that promote coating adhesion. Select features, including developed interfacial area ratio and gradation of thermal residual stress, correlated to adhesive strength values. The understanding of interlocking mesoscale features formed during cold spray informs the parameter selection for depositing metals onto thermoplastics with strong adhesion.
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