The production of Al2Cu intermetallic reinforced copper matrix composite coating by cold gas dynamic spraying process and its characterization

In this study, Al2Cu particle reinforced copper matrix composite coatings have been deposited on commercially pure copper by cold spray process. The target is the improvement mechanical properties of copper without any decrease of electrical conductivity of copper. The experimental studies were started with creating the intermetallic powder. Then, optimisation studies were performed. Optimum parameters were determined with respect to the coating thickness, hardness and oxidation behaviour. After optimization process, coatings were prepared with determinated parameters by cold gas dynamic spray equipment. In order to determine the effect of reinforcement amount on structure of the coatings; the feedstock for the cold spray process was prepared by mixing pure copper powder with Al2Cu powder at different volume ratios (0% to 15 vol.%). Microstructural examinations carry out with optical and scanning electron microscope and mechanical properties determined by the hardness measurements and wear test, also electrical conductivity measurements performed with these coatings. As a result of all process, addition of Al2Cu into copper powders up to 10 vol.% positively affected the cold spray performance of the feedstock. 10 vol.% Al2Cu intermetallic reinforced copper matrix composite coating can be produced for improvement of the surface properties of copper with respect to the results of wear tests, hardness and electrical conductivity measurements.