Abstract

The primary objective of this study was to conduct a comparative analysis of coatings produced using Atmospheric Plasma Spray (APS) and High Velocity Air Fuel (HVAF) processes, applied with Ti-6Al-4V and Sn powders. The coatings were deposited onto a single layer of low-melting polyaryletherketone (LMPAEK) reinforced with vertically aligned carbon fibers (ZRT film). Prior to the application of the spray coating, the samples underwent an electroless plating process with nickel, copper, or silver to serve as interlayers. A systematic comparison was conducted across various combinations of plating metals, thermal spray methods, and coating powders, including unplated baseline samples. The coated samples were characterized using scanning electron microscopy (SEM), confocal laser scanning microscopy (CLSM), and energy dispersive X-ray spectroscopy (EDS). Micro-CT scanning was employed to assess coating porosity. Thermal properties, including thermal conductivity, thermal resistance, and thermal diffusivity, were evaluated using a Thermal Interface Material Analyzer (TIMA). The study demonstrates that optimized thermally sprayed coatings can significantly improve the performance of composite materials, offering enhanced surface and mechanical properties suitable for scalable applications in high-performance, thermally sensitive industries.