Two copper powders were deposited with CGT3000 cold gas dynamic spray system on aluminium substrates. The X-ray diffraction patterns allow the characterisation of the microstructure such as grain size, strain in the coating and dislocation densities. Both powders and coatings have been fully characterised. Three methods have been used to interpret the X-ray patterns: the Warren-Averbach method, the Hall Williamson method and the modified Hall-Williamson method. A comparison between the state of the powders before and after deposition will give an insight on the metallurgical processes that take place during the formation of the coating. The influence of the grain size distribution will also be discussed. This article is a follow up of the publication done at ITSC2006: “Comparison Between Coatings from two Different Copper Powders: Mechanical Properties, Hardness and Bond Strength”.

Cold sprayed copper coatings have been widely studied but the effect of substrate properties and spraying conditions on the bond strength still needs further investigations. Using nanoindentation, it is possible to compare the effect of spray parameters on the change in hardness of the coating due to the difference in size distribution of the powder. Deposition of 2 copper powders on aluminium and Ta6V substrates has been done at different stagnation temperatures and pressures using nitrogen as process gas. Hardness profiles show how the speed of the particles induces shot peening effects on the surface. The interaction between the hot gas jet and the surface may modify the hardness profiles. The effect on the substrate hardness has also been investigated.

The powders of alloys Al 2 O 3 +13wt.%TiO 2 and Al 2 O 3 +40wt.% TiO 2 were plasma sprayed onto aluminum rolls coated initially with Ni20Cr bond deposits. The coatings were subsequently ground, polished and submitted to laser engraving. The engraving, similar to that applied for anilox rolls manufacturing, enabled production of three different patterns with the line densities of 60, 100 and 200 1/cm and depths of about 80, 50 and 10 µm correspondingly. The patterns were engraved under angle of 60° that corresponds to a honeycomb geometry of cells. Emission current, for the electric fields up to 150 V/µm, was in the range of 10-7-10-4A for coatings containing 13 wt.% of titania and, in the range 10-11–10-9 A for that of 40 wt.% of titania. The SEM observations of engraved coating morphology was made in order to find the electron emission spots.

This paper discusses the optimization of HVOF spraying parameters for applying WC-Co and WC-CoCr powders. Coatings produced using the optimized parameters are evaluated based on microstructure, microhardness, and porosity. The influence of the processing method used to produce the powders is also considered along with in-flight particle characteristics. Paper includes a German-language abstract.