Page 71 - MSAM-1-2

Materials Science in Additive Manufacturing Cold spray additive manufacturing of Cu-based materials

body abrasion mechanism, which happens due to the for copper-based cold spray coatings is between 10 µm
detachment of ceramic particles that break the oxide layer and 50 µm to ensure good deposition efficiency. The low
of metal during wear tests. The reported RWRs were 1.0, deposition temperatures also ensure that changes in the
2.7, 3.13, and 5.95 for pure copper, copper-TiB , copper structural and mechanical properties are also minimized,
2
B C, and copper TiC coatings, respectively. The coating and the purpose of the addition of ceramic particles is
4
thickness obtained for copper TiB coatings was 1690 µm, accomplished. The gases used for cold spray deposition
2
which was much higher than that of pure copper (825 µm), have been helium, nitrogen, and air. Helium and nitrogen
copper B C (270 µm), and copper TiC (550 µm). generally can help reduce oxidation. However, the authors
4 who utilized air for cold spray deposition did not report
5. Cold spray deposition parameters and any considerable oxidation of powder particles. The various
properties of copper-based cold spray substrates used for cold spray deposition in the references
coatings by different authors depend on various possible industrial
applications of these coatings according to commercial
Different reinforcements such as Al O , graphite, CNT, acceptance. The applications of such copper-based cold
2
3
WC, MoS , and TiB provide different properties to spray coatings can be for seam and spot welding electrodes,
2
2
the copper-based cold spray coatings. These properties conductors used for high-temperature applications, lead
[29]
vary with the number of reinforcements employed, the wires, electrical contacts, switches, etc. Every material
morphology of powder particles, deposition conditions used as a reinforcement in the copper-based cold spray
implemented, interface bonding characteristics, and coatings serves its intended purpose.
characteristic properties of reinforcements. Table 1 In Table 2, a summary of the properties of various copper-
shows the deposition parameters and compositions of the based cold spray coatings with different reinforcements
copper-based cold spray coatings and their substrates in in the literature is presented. Numerous tests have been
the literature. The particle diameter generally preferred conducted by different authors to verify the effect of

Table 2. Comparison of various properties of copper‑based cold spray coatings
Powder Composition Electrical Friction Wear rates Microhardness Ref.
conductivity coefficient
Copper Pure copper 36 MS/m 0.6 8.6×10 -4 140 – 160 Hv0.3 [23,53,71]
Cu-Al O Cu (50 wt.%), 62% IACS - - 83 – 127 Hv0.3 [30]
2 3
Al O (50 wt.%)
2 3
Cu-Al O – Cu Cu (90, 85, 80, and 70 wt.%), - 0.34 – 0.94 2.53×10 to 1.2×10 -4 114.3 – 88.2 [31]
-4
3
2
coated graphite Al O (10 wt.%) Brinell hardness
3
2
Cu-coated graphite (0, 5, 10, and
20 wt.%)
Cu-CNT Cu 100, 95, 90, 85 - - - 160 – 230 Hv0.1 [45]
CNT 0, 5, 10, 15
Cu-CNT-SiC Cu (95 vol.%)-CNT (5 vol.%) - - - 190 – 260 Hv0.1 [45]
SiC (10 and 20 vol.%)
Cu- MwCNT Cu (97 vol.%) MwCNT (3 vol.%) - - - 303.64 [41]
Cu-graphene Pure copper powder coated with 0.46 5.2×10 -4 [53]
graphene
Cu-MoS Cu 85 vol.%/MoS (15 vol.%) - 0.38 – 0.4 210×10 to 35×10 -6 75 – 132 Hv0.2 [63]
-6
2 2
Cu-MoS -WC Cu 85 vol.%, MoS (14 vol.%), - 0.27 – 0.33 123×10 to 19×10 -6 87 – 135 Hv0.2 [63]
-6
2 2
WC (11 vol.%)
Cu-TiB 2 Cu-12.5 vol% TiB 2 36 MS/m - Relative wear rate (with 156 Hv 0.025 [71]
pure copper as 1) 2.7
Cu-B C Cu-12.5 vol% TiB 2 34.3 MS/m - Relative wear rate 151 Hv 0.025 [71]
4
(with pure copper as 1)
3.13
Cu-TiB Cu-12.5 vol% TiB 35.6 MS/m - Relative wear rate 157 Hv 0.025 [71]
2 2
(with pure copper as 1)
5.95
Volume 1 Issue 2 (2022) 15 https://doi.org/10.18063/msam.v1i2.12