Evaluating the Application of Cold Spray Technology for the Deposition of Copper–Graphene Composite Coatings

The design and implementation of two-dimensional materials into a metal matrix have been the focus of considerable research interest for achieving enhanced properties. Nevertheless, conventional and modern manufacturing techniques often struggle to fabricate bulk 2D metal matrix composites (2DMMCs) while preserving the desired distribution and preventing thermomechanical damage to the constituent phases. Cold spray technology is a solid-state manufacturing method known for maintaining the composition of the original feedstock without causing significant detrimental changes during the deposition process. This study investigates the influence of cold spray process parameters on the microstructure, porosity, and microhardness of copper composites reinforced with 1 wt.% graphene platelets. The copper–graphene composite powder was synthesized via high-energy ball milling and subsequently deposited using two distinct sets of cold spray parameters employing medium- and high-pressure systems. Scanning electron microscopy, dispersive X-ray spectroscopy, porosity measurements, microhardness testing, and Raman spectroscopy were used to comprehensively evaluate the deposits. The findings demonstrate the preservation of the 2D phase and show how cold spray parameters influence porosity, hardness, and the incorporation of graphene within the copper matrix.