The powder morphology (shape and size) of feedstock has a very important role in metal coatings when applied using the cold gas dynamic spray process. In this study, the cold spraying of dendritic Cu powders was investigated. The hydrodynamic processes involved in the dendritic feedstock are complicated to simulate. Compared to particles of the ideal spherical shape, fragmentation of irregularly shaped particles is more severe, and size distribution profiles continuously change in a turbulent stream before the particles arrive at the substrates. Thus, the theoretical effects of particle size on cold sprayed coating properties are nullified. For this reason, it was confirmed that the deposition efficiencies and microscopic morphologies of the dendritic Cu coatings with different particle size distributions were similar to each other because large particles was embedded by the fragmented small particles.
BorchersC., GartnerF., StoltenhoffT., AssadiH. and KreyeH.: ‘Microstructural and macroscopic properties of cold sprayed copper coatings’, J. Appl. Phys., 2003, 93, 10064–10070. doi: 10.1063/1.1573740
2.
GrujicicM., SaylorJ. R., BeasleyD. E., DeRossetW. S. and HelfritchD.: ‘Computational analysis of the interfacial bonding between feed-powder particles and the substrate in the cold-gas dynamic-spray process’, Appl. Surf. Sci., 2003, 219, 211–227. doi: 10.1016/S0169-4332(03)00643-3
3.
BarradasS., MolinsR., JeandinM., ArrigoniM., BoustieM., BolisC., BertheL. and DucosM.: ‘Application of laser shock adhesion testing to the study of the interlamellar strength and coating–substrate adhesion in cold-sprayed copper coating of aluminum’, Surf. Coat. Technol., 2005, 197, 18–27. doi: 10.1016/j.surfcoat.2004.08.222
4.
LiW. Y., LiaoH., LiC. J., LiG., CoddetC. and WangX.: ‘On high velocity impact of micro-sized metallic particles in cold spraying’, Appl. Surf. Sci., 2006, 253, 2852–2862. doi: 10.1016/j.apsusc.2006.05.126
5.
NingX. J., JangJ. H. and KimH. J.: ‘The effects of powder properties on in-flight particle velocity and deposition process during low pressure cold spray process’, Appl. Surf. Sci., 2007, 253, 7449–7455. doi: 10.1016/j.apsusc.2007.03.031
6.
Sudharshan PhaniP., Srinivasa RaoD., JoshiS. V. and SundararajanG.: ‘Effect of process parameters and heat treatments on properties of cold sprayed copper coatings’, J. Therm. Spray Technol., 2007, 16, 425–434. doi: 10.1007/s11666-007-9048-1
7.
LiW. Y., ZhangC., GuoX. P., ZhangG., LiaoH. L., LiC. J. and CoddetC.: ‘Effect of standoff distance on coating deposition characteristics in cold spraying’, Mater. Des., 2008, 29, 297–304. doi: 10.1016/j.matdes.2007.02.005
8.
HanY. K., BirbilisN., SpencerK., ZhangM. X. and MuddleB. C.: ‘Investigation of Cu coatings deposited by kinetic metallization’, Mater. Charact., 2010, 61, 1167–1186. doi: 10.1016/j.matchar.2010.07.011
9.
WielageB., GrundT., RupprechtC. and KuemmelS.: ‘New method for producing power electronic circuit boards by cold-gas spraying and investigation of adhesion mechanisms’, Surf. Coat. Technol., 2010, 205, 1115–1118. doi: 10.1016/j.surfcoat.2010.06.020
10.
LiW. Y., LiC. J. and LiaoH.: ‘Significant influence of particle surface oxidation on deposition efficiency, interface microstructure and adhesive strength of cold-sprayed copper coatings’, Appl. Surf. Sci., 2010, 256, 4953–4958. doi: 10.1016/j.apsusc.2010.03.008
11.
LiJ. F., AgyakwaP. A., JohnsonC. M., ZhangD., HussainT. and McCartneyD. G.: ‘Characterization and solderability of cold sprayed Sn–Cu coatings on Al and Cu substrates’, Surf. Coat. Technol., 2010, 204, 1395–1404. doi: 10.1016/j.surfcoat.2009.09.025
12.
LiC. J., WangH. T., ZhangQ., YangG. J., LiW. Y. and LiaoH. L.: ‘Influence of spray materials and their surface oxidation on the critical velocity in cold spraying’, J. Therm. Spray Technol., 2010, 19, 95–101. doi: 10.1007/s11666-009-9427-x
13.
KoivuluotoH. and VuoristoP.: ‘Effect of powder type and composition on structure and mechanical properties of Cu+Al2O3 coatings prepared by using low-pressure cold spray process’, J. Therm. Spray Technol., 2010, 19, 1081–1092. doi: 10.1007/s11666-010-9491-2
14.
NakanoH., YamadaM., FukumotoM. and YamaguchiE.: ‘Microstructure of interfacial region between cold-sprayed copper coating and AlN substrate coated with sputtered titanium and copper’, J. Therm. Spray Technol., 2011, 20, 407–411. doi: 10.1007/s11666-010-9522-z
15.
VenkateshL., ChavanN. M. and SundararajanG.: ‘The influence of powder particle velocity and microstructure on the properties of cold sprayed copper coatings’, J. Therm. Spray Technol., 2011, 20, 1009–1021. doi: 10.1007/s11666-011-9614-4
16.
EasonP. D., FewkesJ. A., KennettS. C., EdenT. J., TelloK., KaufmanM. J. and TiryakiogluM.: ‘On the characterization of bulk copper produced by cold gas dynamic spray processing in as fabricated and annealed conditions’, Mater. Sci. Eng. A, 2011, A528, 8174–8178. doi: 10.1016/j.msea.2011.07.012
17.
KoK. H., ChoiJ. O. and LeeH.: ‘Intermixing and interfacial morphology of cold-sprayed Al coatings on steel’, Mater. Lett., 2014, 136, 45–47. doi: 10.1016/j.matlet.2014.07.142
