Copper-Based Composite Coatings by Solid-State Cold Spray Deposition: A Review

Abstract

Copper (Cu)-based composite coatings have been widely applied in all kinds of important industry fields due to their outstanding comprehensive properties. The preparation temperature of a composite coating is the key factor affecting the properties, so the cold spray (CS) technology is characterized by low-temperature solid-state deposition, which ensures its emergence as the most promising technology for preparing the Cu-based composite coatings. In this paper, first, the principle of CS technology and the deposition mechanism of the coatings are introduced. On this basis, the deposition mechanism of Cu-based metal/ceramic composite coatings is further explored. Secondly, the effects of key CS process parameters (particle velocity, particle morphology, and substrate state) on the quality of the Cu-based composite coatings are summarized, and the current research status of cold-sprayed Cu-based composite coatings in the fields of corrosion resistance, wear resistance, self-lubricating properties, and electrical conductivity is reviewed. Moreover, the improvement of the performance of Cu-based composite coatings by various post-process treatments of coatings, such as heat treatment (HT) and friction stir processing (FSP), is elaborated. Finally, the future development of Cu-based composite coatings and CS technology is prospected.

Comparison of Cold-Sprayed Coatings of Copper-Based Composite Deposited on AZ31B Magnesium Alloy and 6061 T6 Aluminum Alloy Substrates

“…However, the adhesion of the coatings sprayed on the AZ31B magnesium alloy substrate is entirely higher than that of the coatings deposited on the 6061 T6 aluminum alloy substrate at 900 °C and different gas pressures. This indicates that the interfacial bonding strength of the coatings is mainly influenced by the substrate hardness [ 34 ].…”

“…As the gas pressure increases, the adhesion of the coatings deposited on the AZ31B magnesium alloy substrate is higher than that of the coatings deposited on the 6061 T6 aluminum alloy substrate at 600 • C, 700 • C, and 800 • C. However, the adhesion of the coatings sprayed on the AZ31B magnesium alloy substrate is entirely higher than that of the coatings deposited on the 6061 T6 aluminum alloy substrate at 900 • C and different gas pressures. This indicates that the interfacial bonding strength of the coatings is mainly influenced by the substrate hardness [34]. The typical SEM images of scratches of the Cu@Gr/CC coatings deposited on the two different substrates at 800 °C and 5.5 MPa are illustrated in Figure 11a,b, respectively.…”

Preparation of Highly Stable and Cost-Efficient Antiviral Materials for Reducing Infections and Avoiding the Transmission of Viruses such as SARS-CoV-2

“…In this regard, different technologies have been developed in the preparation of copper compounds as coating agents, for example, in the fabrication of face masks or antiviral textiles. − Especially in the last 2 years, different products containing copper materials have been commercialized, mainly using a mixture of species such as Cu 2 O or CuO, or directly using the bulk copper. − This poses several questions because the amount of copper is extremely high and could have important toxicity problems. Also, some of these species need to be provide copper ion release to be effective.…”

Laser Texturing to Increase the Wear Resistance of an Electrophoretic Graphene Coating on Copper Substrates

“…Over the years, copper and its alloys have played a critical role in the industrial and metallurgical sectors since properties such as ductility and conductivity ensure extensive involvement in many fields [1,2], even under wear conditions [3]. However, unsatisfactory mechanical properties such as hardness strength and wear resistance limit the application of copper and its alloys, especially under high-temperature operating conditions [4][5][6]; hence, improving wear resistance to increase the service life of copper-based components is an urgent need [3].…”

“…At present, surface treatment technologies such as thermal spraying, electroplating, laser cladding, magnetron co-sputtering, and plasma cladding are widely exploited to coat a protective layer on copper substrates and increase friction wear performance and service life [6][7][8][9][10][11][12][13][14]. Copper-based nanocomposites produced through these methods have shown a growing trend in copper surface protection due to their improved mechanical properties, leaving the physical performance of both the substrate and the matrix unaffected, thus enhancing the wear resistance through improved lubricating capability [15][16][17].…”