Integrating Titanium Coating with 3D-Printed GFRP Panels: An Innovative Approach to Harnessing Composite Strengths in Engineering Applications

This study explores the merging of metals and polymers to harness their distinct characteristics for numerous engineering applications. The focus of the study is on integrating the lightweight and robust mechanical properties of Glass Fibre-Reinforced Plastics (GFRP) with the superior hardness and wear resistance property of metals. This is achieved by applying a titanium (Ti) particle coating to three-dimensional-(3D-)printed GFRP panels. The GFRP panels were created using Fused Filament Fabrication (FFF), while the titanium particles were deposited by Cold Spray (CS) technique. The panels were produced with different layering sequences to study the implications of different stratification patterns, and the Cold Spray parameters were fine-tuned for optimal deposition. The process efficacy and parameter influence were assessed through methods like adhesion testing, distortion checks, cross-sectional analysis, and surface coverage assessments. The combined FFF of GFRPs and Cold Spray Deposition (CSD) of titanium resulted in impressive adhesion strength (about 4 MPa) and almost total surface coverage. The embedded fibres in the GFRP enhanced the substrate rigidity, mitigating distortion effects. It was also discerned that the 3D-printing settings influenced deposition outcomes. For instance, raising the interior fill density between 20% and 60% enhanced bonding strength by approximately 40%. In summary, the research confirms the effectiveness of the method, paving the way for further exploration.