Cold spray (CS) is characterized as a solid-state process of high deposition efficiency for metallic coatings as well as additive manufacturing of metals. However, due to high velocity impact and extensive deformation of particles during CS, the as-received coatings or deposits may present anisotropic characteristics which could influence the performance of deposits. Hence this study aims to investigate the anisotropic behaviors of CS copper deposits in a systematic way. The microstructure and micromechanical properties of the deposits both in the cross-section (v-face) and in the parallel plane to the surface (p-face) were characterized. Tensile tests were performed at various loading angles with respect to the nozzle moving direction in the p-face. It is revealed that there exist strong microstructural and mechanical anisotropies in CS deposits. Different interparticle interaction results in more severe particle impact deformation in v-face than p-face, with larger elastic modulus and microhardness values. The tensile tests show an unexpected anisotropy in both ultimate tensile strength and elongation, with the highest performance occurring at the angle of 20°. The in-plane tensile anisotropy could be attributed to the parallel multiple passes. Therefore, a novel weave-spraying method was proposed, which can greatly reduce the tensile anisotropy of CS deposits.

In this paper, a preliminary analysis on the residual stress evolution of cold-sprayed coatings taking copper coating as an example was performed. An integrated frame of calculation was proposed based on the simulation results obtained from the developed thermo-mechanically coupled Eulerian model. In a single Cu splat, the residual stress appears to be large tensile stress near the surrounding area of the interface and be small tensile stress at the bottom. In single pass Cu coating, the residual stress is variable and there exists not only compressive stress but also tensile stress. When the impacting velocity changes, the resultant residual stresses also vary in both cases. The present simulated results were related to the reported experiments by others, while there is much difference.