Metallization of Polymeric Structures With a Hybrid Thermal Spray - Laser Cladding Process

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The immediate industry problem that Group Six Technologies and the University of Alberta wish to resolve under the auspices of this Engage Grant is the development of a hybrid fabrication process that utilizes thermal spraying and laser cladding to deposit thick metal and ceramic- or cermet-reinforced metal layers on to polymeric structures. It is envisaged that these metal or metal-reinforced layers will serve to provide wear protection to the polymeric structures while contemporaneously generating heat energy, when needed, to serve in anti-icing or de-icing protocols. In the wind turbine and aerospace industries, polymeric materials such as carbon fiber-reinforced polymers (CFRP) are used as the material of choice to fabricate airfoil structures such as the turbine blades and wings; however, due to the low thermal conductivity of these materials, ice formation on the airfoils during operation causes the disruption of boundary layers, increases drag, and poses serious safety problems. Therefore, the development of novel anti-icing or de-icing systems that can be easily mass-produced and that can provide surface heating would be ideal to improve the performance and safe operation of the airfoils.