Characterization and evaluation of plasma-sprayed coatings on polymeric substrates

This study investigates the application of atmospheric plasma spray (APS) technology for metallizing two distinct types of polymeric substrates—thermosets and thermoplastics—using metallic coatings composed of materials with varying and higher melting points, such as zinc, aluminum, and copper. Due to their differences in thermal characteristics, these two categories of polymers are expected to respond differently to the spraying process, influencing coating adhesion and hence, overall coating integrity. The research examines the effects of metallization process parameters and the impact of pre- treatment conditions, on the adhesion strength of the coatings. Furthermore, the role of the physical properties of each substrate is analyzed to better understand their influence on adhesion. To elucidate adhesion mechanisms, a detailed investigation of the coating-substrate interfaces was conducted. While the study provides valuable insights into the metallization of polymeric substrates using APS, further optimization of process parameters is necessary to enhance adhesion performance and ensure the long-term durability of the coatings.