Characterization of copper layers produced by cold gas-dynamic spraying

The cold gas-dynamic spray method produces coatings or deposits by introducing solid feedstock particles into a supersonic gas stream developed through the use of a converging-diverging (de Laval) nozzle. The particles thus accelerated impact on a substrate surface and develop into a dense deposit through a process believed to be similar to cold compaction. The work reported here explores the internal nature and physical characteristics of copper deposits produced by the cold gas-dynamic spray method using two vastly different starting powders: in one case, a spongy copper obtained by a direct-reduction process, and in the second, a denser, more spheroidal particulate produced by gas atomization. Optical and electron microscopies (scanning electron microscopy [SEM] and transmission electron microscopy [TEM]) were used to observe details of microstructure in the feedstock particles and deposits. Young's modulus and residual stress measurements for the deposits were obtained through mechanical means, and measurements of hardness and electrical conductivity are reported. The internal structure of the cold-spray deposit was influenced by the surface purity of the feedstock material.