Selection of the spraying technologies for over-coating of metal-stampings with thermo-plastics for use in direct-adhesion polymer metal hybrid load-bearing components

The suitability of various polymer-powder spraying technologies for coating of metal-stampings used in polymer metal hybrid (PMH) load-bearing automotive-component applications is considered. The suitability of the spraying technologies is assessed with respect to a need for metal-stamping surface preparation/treatment, their ability to deposit the 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 while each of the spraying technologies has some limitations, the cold-gas dynamic-spray process appears to be the leading candidate technology for the indicated applications.