This study investigates the deposition behavior of cold sprayed copper particles on flat surfaces. In the experiments, a Laval-barrel nozzle was used to spray water atomized spherical copper particles with a mean diameter of 5 µm onto mirror-polished stainless steel. The particles were similar in morphology regardless of spraying conditions with an average bonding strength of 60 MPa as determined by nano scratch (shear) testing. An amorphous-like layer at the particle-substrate interface indicates that the deformation of the particles initially destroys their surface oxide, revealing an active fresh surface that facilitates metallic bonding. At higher spray velocities, metal jetting is observed at the periphery of flattened particles and its relationship with deposition efficiency is statistically analyzed and put forth as a potential method for controlling the cold spray process.

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