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Bonding Mechanisms in Cold Spray: Influence of Surface Oxidation During Powder Storage

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Abstract

Cold spray is a solid-state process in which solid particles are subjected to severe plastic deformation to form a coating. The effect of naturally occurring oxides on bonding in the cold spray was investigated in this work. Deposition characteristics of copper powder with different surface oxide thicknesses on steel substrate were examined using a local pull-off test. This enables the investigation of individual particle/substrate interfaces. X-ray photoelectron spectroscopy was used to study thoroughly the powder surface chemistry and the oxide thickness as a function of exposure time. This study revealed that the oxide film thickness grew from 6 nm for the as-received powder to 11.6 nm after 2 months of exposure to atmospheric conditions. Scanning electron microscopy and x-ray energy dispersive spectroscopy were used to characterize the particle/substrate interfacial bonding. Adhesion test results show that the bond strength is highly influenced by the surface oxide thickness. Different bonding behaviors and a drop in coating deposition efficiency were observed as the oxide thickness increased. Finite element simulations supplemented our understanding of the particle adhesion dynamics as the oxide film thickness increases. They were also used to study the surface oxide cleanup and bonding mechanism for particles with different oxide film thicknesses.

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  1. Cold Spray Research Laboratory, University of Ottawa, Ottawa, ON, Canada

    Maryam Razavipour, Saeed Rahmati & Bertrand Jodoin

  2. CECS, Universidade Federal do ABC, Santo André, SP, Brazil

    Alejandro Zúñiga

  3. CCNH, Universidade Federal do ABC, Santo André, SP, Brazil

    Denise Criado

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  1. Maryam Razavipour
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Razavipour, M., Rahmati, S., Zúñiga, A. et al. Bonding Mechanisms in Cold Spray: Influence of Surface Oxidation During Powder Storage. J Therm Spray Tech 30, 304–323 (2021). https://doi.org/10.1007/s11666-020-01123-5

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