Matrood, G., Abdulkader, N., Ali, N. (2024). Investigating the effect of spray parameters on adhesion strength between aluminum coatings and polymeric substrate. , 42(12), 1484-1494. doi: 10.30684/etj.2024.155226.1850
Ghufran J. Matrood; Niveen J. Abdulkader; Nahedh M. Ali. "Investigating the effect of spray parameters on adhesion strength between aluminum coatings and polymeric substrate". , 42, 12, 2024, 1484-1494. doi: 10.30684/etj.2024.155226.1850
Matrood, G., Abdulkader, N., Ali, N. (2024). 'Investigating the effect of spray parameters on adhesion strength between aluminum coatings and polymeric substrate', , 42(12), pp. 1484-1494. doi: 10.30684/etj.2024.155226.1850
Matrood, G., Abdulkader, N., Ali, N. Investigating the effect of spray parameters on adhesion strength between aluminum coatings and polymeric substrate. , 2024; 42(12): 1484-1494. doi: 10.30684/etj.2024.155226.1850

Investigating the effect of spray parameters on adhesion strength between aluminum coatings and polymeric substrate

Engineering and Technology Journal
Volume 42, Issue 12, December 2024, Pages 1484-1494    PDF (1.22 M)
Document Type: Research Paper
DOI: 10.30684/etj.2024.155226.1850
Authors
Ghufran J. Matrood* ; Niveen J. Abdulkader; Nahedh M. Ali
Materials Engineering Dept., University of Technology-Iraq, Alsina’a street, 10066 Baghdad, Iraq.
Abstract
Metallization involves applying a thin metal layer onto a substrate, typically through techniques such as thermal spraying. This process improves conductivity, durability, and aesthetic appeal, making it valuable in applications such as electronics, solar panels, and decorative coatings. In this study, flame thermal spray technique are used to metalize high-density polyethylene with an aluminum layer. Taguchi and ANOVA are used to investigate the effect of various parameters on the adhesion strength between aluminum layers deposited on high-density polyethylene (HDPE) substrates. DOE utilization has facilitated the identification of the effects of the flame thermal spraying parameters, such as the distance between the spray gun and substrate, the spray velocity, the powder feed rate, and the delay time, on the adhesion strength. The orthogonal matrix resulting from the Taguchi method corresponded to an L9 (34) matrix, which was utilized to decrease the number of experiments from 81 to 9. To attain optimal adhesion strength, it is essential to maintain a distance of 250 mm between the gun spray and the substrate, utilize a powder feeding rate of 15 g/minute, achieve a spraying velocity of 300 m/min, and implement a delay time of four minutes. The X-ray diffraction shows that there is no oxidation in the coating layer. Moreover, the aluminum layer shows good electrical conductivity (2.08×104 Ω-1.cm-1). Using Taguchi and ANOVA leads to optimizing processes efficiently with fewer trials, improving product quality by reducing variability, and making informed decisions on which factors to control for optimal performance.

Highlights
  • Metallic coatings on HDPE substrates were studied using the flame thermal spray technique.
  • The effect of thermal spray parameters on adhesion strength was investigated.
  • Metallic powder enabled successful coating without damaging the polymeric substrate.
Keywords
Thermal spray; Aluminum; HDPE; Electrical conductivity; Taguchi methodology
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