To improve the microstructure and properties of Cu coating prepared by cold spraying, the plasma heating is used during the cold spraying process. The models of Cu particles deposited on a Cu substrate during cold spraying process without/with plasma heating are established and calculated, and the results are compared. The calculated results show that the plasma heating causes copper particles and substrates to produce greater plastic deformation during deposition. The microstructure of Cu coating prepared by cold spraying with plasma heating is experimentally investigated. Plasma heating can effectively reduce the porosity of the copper coating, improve the binding between the coating and the substrate, and reduce the grain size of the coating, which is due to the greater deformation of the copper particles under plasma heating. The experimental results are consistent with the calculation results. The results of the coating immersion experiments show that the corrosion rate of the Cu coating prepared by plasma‐assisted low‐pressure cold spraying is reduced from 1.5 to 0.094 mg cm−2 h compared with the samples prepared without plasma heating under the same conditions, which is due to the reduced porosity of the coating.
Aluminum target material is an important target material and is widely used in preparations of semiconductor films, integrated circuits, display circuits, protective films, decorative films, etc. In this study, pure aluminum coatings were deposited on stainless steel substrates by cold-spray technology as part of an overall project to produce large-size pure aluminum sputtering target materials. The results show that pure aluminum coatings exhibit high adhesive strength (~98 MPa), high deposition efficiency (~95%), and low porosity (~0.3%) on stainless steel substrates. The bonding mechanisms of pure aluminum coatings on stainless steel are a combination of metallurgical and mechanical interlocking. The evolutions of microstructure and mechanical properties of pure aluminum coatings under different heat treatments were also studied. With the increase of heat treatment temperature, it is found that cold-sprayed aluminum coatings become more homogenous in microstructure, the microhardness is reduced, and the adhesive strength seems to be slightly reduced. Overall, this study demonstrates significant advantages of cold-spray technology in depositing high-performance pure aluminum coatings on stainless steels.
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