COLD SPRAY SURFACE PATTERNING OF ALUMINUM ON ALUMINUM, SILICON, GLASS, AND PRINTED CIRCUIT BOARD SUBSTRATES
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Authors
Palao, Jonathan E.
Subjects
cold spray
surface patterning
surface modification
functional coating
surface patterning
surface modification
functional coating
Advisors
Wu, Chun-Hsien
Date of Issue
2017-12
Date
December 2017
Publisher
Monterey, California. Naval Postgraduate School
Language
Abstract
The aim of the present study is to investigate the feasibility of and the criteria for using the
cold spray technique for surface patterning to create two-dimensional surface features on
various substrates. Metal meshes were used as screens for surface patterning in this
investigation; fabricated features were characterized with optical microscope, scanning electron
microscope, and optical profilometer. Processing parameters like mesh size, standoff distance,
gun traverse speed, and number of spray passes were examined to study their influence on the
morphology of the fabricated features. Two-dimensional aluminum features were successfully
fabricated on aluminum, soda-lime glass, silicon wafer, and the copper foil-layer of printed circuit
board. The smallest feature, created with -45 to +5 µm aluminum feedstock powders, has an
average size of 67.4 µm. It was determined that the pore size of a mesh needs to be at least 3.3
times bigger than the average size of feedstock powders in order to create features successfully.
To estimate the probability of feedstock powders passing through a mesh and simulate the
topography of the fabricated features, a Monte Carlo simulation incorporating the particles’ size
distribution and the geometry meshes was developed. With the capability of creating features on
diverse substrates, the cold spray surface patterning technique shows promising potential to
create heterogeneous two-dimensional functional features or devices at micron size with high
efficiency.
Type
Thesis
Description
Series/Report No
Department
Mechanical and Aerospace Engineering (MAE)
Organization
Identifiers
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