Surface pre-treatment and its influence on electric functionality and the formability of screen printed steel sheet

Industrial development focuses on multifunctional components due to rising requirements regarding e.g. light weight and security. A beneficial possibility to extend the functionality of structural components produced by metal forming is the usage of screen printed metal blanks. During the printing process insulating and electric inks are applied. The examined printed layer structure consists of three insulating full area layers and one conductive layer in the form of strain gauges. The two applied inks are solvent-based and printed with a half-automatic machine. To improve the adhesion and electric functionality, the impact of different mechanical and physical surface pre-treatments on the electrical characteristics is investigated in tensile tests. In particular, abrasive peening, ball peening, grinding and polishing (mechanical) and in addition plasma and corona technology (physical) were utilised. Contrary to expectations, the surface pre-treatment does not affect the adhesion to the steel sheet. The cracking of the printed strain gauges takes place prior to the delamination of the coating. Explanatory models are elaborated. They are based on the measurements of roughness, surface energy, edge sharpness and the electrical resistance of printed conductive structures before, during and after forming.