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<p>This study examined the interfacial degradation behavior of cold-sprayed Sn coatings deposited on carbon fiber–reinforced polymer (CFRP) substrates under cyclic thermal loading. The coated specimens were subjected to thermal cycling up to 1000 cycles in order to evaluate the evolution of interfacial damage and its influence on the mechanical response of the coating system. Cross-sectional observations revealed degradation of the Sn/CFRP interface during thermal cycling, starting with small localized gaps in epoxy-rich regions and progressing to more extended interfacial separation at higher cycle numbers. This degradation was accompanied by a gradual reduction in adhesion strength from approximately 8.5 ± 0.2&#xa0;MPa in the as-sprayed condition to 4.6 ± 0.9&#xa0;MPa after 1000 thermal cycles, indicating increased heterogeneity of interfacial load transfer. Moreover, atomic force microscopy revealed gradual changes in the surface topography after thermal cycling, suggesting progressive redistribution of stresses within the Sn coating due to weakening of the Sn/CFRP interface. Nanoindentation measurements near the interface further demonstrated a progressive decrease in hardness from approximately 0.424 GPa in the as-sprayed condition to 0.278 GPa after 1000 thermal cycles, accompanied by increased local compliance, while the bulk coating remained mechanically stable. The combined results indicate that thermal cycling primarily weakens the interfacial support between the Sn coating and the CFRP substrate rather than causing intrinsic damage within the coating itself. These findings provide insight into the long-term reliability of cold-sprayed metallic coatings on polymer-based composites operating under thermally fluctuating environments.</p>

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Interfacial degradation of cold-sprayed Sn coatings on CFRP under thermal cycling

  • 期刊论文

  • 发表日期：

    2026年6月18日

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  • Feras Alnaimat,
  • Raman Kumar,
  • Dilipkumar S. Patel,
  • Tariq Abdulkader Alrihaim,
  • N. Beemkumar,
  • Akanksha Mishra,
  • Dhirendra Nath Thatoi,
  • Harjot Singh Gill

摘要

This study examined the interfacial degradation behavior of cold-sprayed Sn coatings deposited on carbon fiber–reinforced polymer (CFRP) substrates under cyclic thermal loading. The coated specimens were subjected to thermal cycling up to 1000 cycles in order to evaluate the evolution of interfacial damage and its influence on the mechanical response of the coating system. Cross-sectional observations revealed degradation of the Sn/CFRP interface during thermal cycling, starting with small localized gaps in epoxy-rich regions and progressing to more extended interfacial separation at higher cycle numbers. This degradation was accompanied by a gradual reduction in adhesion strength from approximately 8.5 ± 0.2 MPa in the as-sprayed condition to 4.6 ± 0.9 MPa after 1000 thermal cycles, indicating increased heterogeneity of interfacial load transfer. Moreover, atomic force microscopy revealed gradual changes in the surface topography after thermal cycling, suggesting progressive redistribution of stresses within the Sn coating due to weakening of the Sn/CFRP interface. Nanoindentation measurements near the interface further demonstrated a progressive decrease in hardness from approximately 0.424 GPa in the as-sprayed condition to 0.278 GPa after 1000 thermal cycles, accompanied by increased local compliance, while the bulk coating remained mechanically stable. The combined results indicate that thermal cycling primarily weakens the interfacial support between the Sn coating and the CFRP substrate rather than causing intrinsic damage within the coating itself. These findings provide insight into the long-term reliability of cold-sprayed metallic coatings on polymer-based composites operating under thermally fluctuating environments.