This study demonstrates a new approach for producing thick copper coatings on steel by cold spraying via nitrogen gas. To overcome delamination problems without resorting to helium, substrate surfaces are treated prior to deposition using a forced-pulse waterjet. Samples with different levels of roughness were prepared using both conventional and waterjet surface treatments. The samples were then coated with thick Cu using only N2 and adhesion tests were performed. Test results show good coating adhesion on all waterjet treated substrates with bond strengths ranging from approximately 25 MPa to 58 MPa, depending on surface roughness. Consistent with previous studies, cold spray Cu did not adhere to any substrates that had been polished or grit blasted. It is shown that the pulsed waterjet creates a surface with anchoring features that interlock with incoming particles to form a strong mechanical bond.
In this work, fully dense titanium parts are fabricated by cold gas dynamic spraying (CGDS). Titanium powder is deposited using a low-pressure CGDS process with nitrogen as the carrier gas. The density, porosity, hardness, and tensile properties of the parts produced are determined and discussed.
This study investigates the effect of nozzle material on cold sprayed aluminum coatings produced using a downstream lateral injection system. It is shown through experimentation that nozzle material has a significant impact on deposition efficiency and particle velocity. It is proposed that the effects are related to complex interactions between particles and internal nozzle walls. The results obtained lead to the conclusion that nozzles with higher thermal diffusivity transfer more heat to particles when they make contact with internal surfaces, which increases deposition efficiency even though particle velocities are reduced.
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