The Influence of Powder Particle Velocity and Microstructure on the Properties of Cold Sprayed Copper Coatings

Abstract

No literature exists on the influence of the velocity of Cu powder particles (during cold spraying) on the properties of the coatings like porosity, hardness, electrical conductivity, residual stress, and microstructure. Similarly, though the occurrence of dynamic recrystallization in the Cu powder particle during its deformation under the cold sprayed process has been well documented, its influence on the properties of the coating has not been studied. In this study, it is shown that while porosity of the coating is determined directly by the powder particle velocity, the other properties like hardness, electrical conductivity, and residual stress are determined not only by the particle velocity which depends on stagnation pressure and preheating temperature of the air (process gas) but also additionally on preheating temperature of air per se. The extent of powder particle fragmentation and dynamic recrystallization as a function of particle velocity has been quantified in terms of the grain boundary area fraction and the influence of the latter parameter on the coating properties has also been presented.

The influence of process parameters and heat treatment on the properties of cold sprayed silver coatings

“…Thus, the influence of coating process variables (air preheat temperature and stagnation pressure) is restricted only to the extent of their influence on V p . In contrast, in the case of copper coating as shown earlier by the present authors [35], V p does not correlate uniquely with the coating properties and that air preheating has an additional effect over and above the effect it has on V p , unlike in the case of Ag. Similarly, the hardness of the Cu coating also does not correlate uniquely with V p [35], In our opinion, such a behavior is related to the fact that in the as-coated condition, Cu coating is composed of poorly bonded splats as reflected by its low electrical conductivity (see Fig.…”

Corrosion resistance and antibacterial properties of copper coating deposited by cold gas spray

“…The cold gas spray (CGS) technique is a useful methodology for obtaining surfaces covered by copper, enabling the preparation of thick copper coatings with high adhesion and good resistance to corrosion and wear, at low cost [11][12][13][14][15][16][17][18][19][20]. CGS is a solid-state process in which particles are heated below their melting point at temperatures that can vary according to the nozzle design, gas, and spraying parameters used [13,[21][22][23][24].…”

Supersonic Cold Spraying for Energy and Environmental Applications: One‐Step Scalable Coating Technology for Advanced Micro‐ and Nanotextured Materials

“…In addition to the above-mentioned works, many other groups have studied coldspraying and mechanical properties of various micrometer-scale metal particles including Cu, [65][66][67][68][69] Al, [65,70,71] Ni, [72] and alloys [73][74][75][76][77][78][79] (Figure 4 and Table 2). While this additional work has led to significant progress in metal cold-spraying techniques, the methods used to analyze cold-sprayed metal coatings have been similar to the previous studies.…”