Copper matrix composite coatings produced by cold spraying process for electrical applications

Composite coatings were deposited on commercially pure copper substrates by cold spraying of feedstock consisted of copper and Al2Cu powders. The amount of the Al2Cu powder incorporated in the feedstock varied in between 0 and 15 vol.%. Characterisations of the coatings were done by microstructural examinations, hardness and electrical conductivity measurements and wear tests. Composite coatings deposited from the feedstock containing 5 and 10 vol.% Al2Cu powder exhibited better electrical conductivity and superior wear resistance than the monolithic (Al2Cu free) copper coating. Presence of 15 vol.% Al2Cu in the feedstock diminished both the wear resistance and the electrical conductivity of the coating.