Influence of Feedstock in the Formation Mechanism of Cold-Sprayed Copper Coatings

The aim of this article is to investigate the characterizations and formation mechanisms of cold-sprayed coatings using gas-atomized and electrolytic powders. The study highlights the importance of reaching the particles’ critical velocity for optimal deposition. The main findings reveal that the morphology and stacking conditions of the coatings have a significant impact on their mechanical properties. Coatings made with gas-atomized powders exhibited noticeable pores and higher plastic deformation, while electrolytic powder coatings had greater density and smoother interfaces with the substrate. Adhesion strength relied on the physical bonding resulting from the plastic deformation energy between the spraying powders and the substrate. Gas-atomized powders showed higher adhesion compared to electrolytic powders, with dendritic powders resulting in lower adhesion due to dispersed impact force. The interaction between thermal and kinetic energy during the cold spraying process facilitated plastic deformation and particle deposition by softening and eroding the substrate surface. Insufficient plastic deformation with dendritic powders led to incomplete overlap, pore formation at the interface, and the persistence of the oxide layer along powder boundaries. Overall, these findings provide valuable insights into the influence of powder properties on coating morphology, adhesion strength, and overall performance, contributing to the understanding and optimization of cold spray processes.