Impact behaviour of a novel composite structure made of a polymer reinforced composite with a 3D printed metallic coating

Abstract The low-velocity impact behaviour of novel composite structures, made of a polymer matrix composite with a superficial 3D printed metallic layer, was studied. The metallic layer was produced through cold spray deposition which is a relatively new additive coating technique allowing for the deposition of metallic coatings on thermal-sensitive substrates, such as the polymeric materials. Micron-sized aluminium particles were used to metallise the surface of basalt-nylon 6 (PA6) laminates manufactured by the compression moulding technique. Three different energy levels (10J, 20J, 30J) were set for the impact tests. The results obtained pointed out the beneficial contributions of the metallic coating on the energy absorbing modes of the polymeric substrates; the positive effects on the damage mechanisms as well as the crack propagation were detected by plastic deformation analyses and ultrasonic damage controls.