In-mold metallization of composite structures

摘要

A method of forming a surface coating on a composite article may include applying a thermal spray to a tool surface of a tool in such a manner as to form a surface coating having a releasable bond with the tool surface. The method may further include applying composite material over the surface coating, curing the composite material to form a cured composite article, and removing the cured composite article from the tool in a manner that releases the surface coating from the tool surface and retains the surface coating with the cured composite article.

主权项

1. A method of forming a surface coating on a composite article, comprising the steps of:
determining parameters of a thermal spray that result in a magnitude of net residual stress in a surface coating being substantially equivalent to a tool-coating adhesion strength; applying the thermal spray to a tool surface of a tool in such a manner as to form the surface coating having the net residual stress substantially equivalent to the tool-coating adhesion strength and such that the tool-coating adhesion strength is less than a bond at a part-coating interface between the surface coating and a cured composite article; applying composite material over the surface coating; curing the composite material to form the cured composite article bonded to the surface coating at the part-coating interface; and removing the cured composite article from the tool in a manner that releases the surface coating from the tool surface and retains the surface coating with the cured composite article.