A computational analysis and suitability assessment of cold-gas dynamic spraying of glass-fiber-reinforced poly-amide 6 for use in direct-adhesion polymer metal hybrid components

A transient non-linear dynamics computational analysis of cold-gas dynamic spraying (CGDS) of glass-fiber-reinforced poly-amide (nylon) 6 has been carried out using Ansys-Autodyn [Century Dynamics Inc., Ansys-Autodyn Version 11.0, User Documentation, Century Dynamics Inc. (a subsidiary of ANSYS Inc.), 2007] in order to assess the suitability of this spraying technology for coating of metal stampings used in polymer metal hybrid (PMH) load-bearing automotive component applications. In addition, the suitability of the CGDS is assessed with respect to a need for metal stamping surface preparation/treatment, the ability to deposit polymeric material without significant material degradation, the ability to selectively overcoat the metal stamping, the resulting magnitude of the polymer-to-metal adhesion strength, durability of the polymer/metal bond with respect to prolonged exposure to high-temperature/high-humidity and mechanical/thermal fatigue service conditions, and compatibility with the automotive body-in-white (BIW) manufacturing process chain. The analysis revealed that CGDS can be considered as a viable technology for coating of metal stampings used in PMH load-bearing automotive component applications.