In the Cold Gas Dynamic Spray (CGDS) process, coatings are deposited by the virtue of the high particle velocity achieved by the use of converging-diverging (de Laval) nozzle along with suitable particle characteristics and process parameters. In this study copper coatings were deposited on aluminium substrates using helium as the accelerating gas. The influence of the CGDS conditions, primarily driving gas temperature and pressure, on the nature of the deposited coatings and the deposition efficiency of the process were investigated. The results indicate that it is possible to deposit copper coatings at a wide range of process conditions, with successful deposition being observed with the driving gas at room temperature and 11 bar pressure (a condition where the nozzle is still choked). However, the nature of the coatings is strongly dependent upon the processing conditions. With room temperature driving gas, an increase in pressure lead to an increase in deposition efficiency, and increase in substrate deformation and an increase in microhardness in the deposit due to higher levels of work hardening. The use of driving gas at temperatures as low as 473 K resulted in recrystallisation in the deposit and a decrease in tendency to debond due to stress relief during recrystallisation. Recrystallisation also manifested itself in reduced hardness. The sensitivity of the recrystallisation conditions to the traverse speed of the jet over the substrate indicated that these processes are initiated by the impingement of the hot gas jet onto the deposit following deposition and not by changes in velocity or temperature of the particles upon impact.

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