Optimization study on wet electrostatic powder coating process to manufacture UHMWPE/LDPE towpregs

In the present study, an attempt has been made to coat the non-conductive Ultra-high Molecular Weight Polyethylene (UHMWPE) fibers with Low-Density Polyethylene (LDPE) powder. In order to enable the deposition of electrostatically charged LDPE powder onto the fiber surface, UHMWPE fibers are dipped into a surface modification bath to impart momentary conductivity. Further, Box Behnken’s experimental design is used to optimize the processing parameters for Fiber Volume Fraction (V _f ) for this wet electrostatic spray coating process. An experimental multi-parametric equation is acquired through response surface methodology to ascertain the association amid the process parameters such as processing temperature (A), conveying air pressure (B), and gun nozzle angle (C) on the output response of V _f . The process parametric values for A, B, and C are varied from 225°C to 245°C, 0.2 bar to 0.4 bar, and 0° to 120° respectively. The V _f obtained is in the range of 37.02%–56.28% depending on the combination of process parametric values. Powder pick-up increases with an increase in the gun nozzle angle. An increase in conveying air pressure and temperature of the hot air oven leads to an increase in powder deposition. The values predicted from the model are observed to be in close proximity (94.59%) to the experimental results. Gun nozzle angle is the principal parameter affecting the matrix deposition on the fiber surface in comparison to other process parameters.