Effects of spark-plasma sintering treatment on cold-sprayed copper coatings

Cold-spray is well known as an effective coating technique to make thick metallic coatings. However, cold-sprayed metallic coatings usually have low tensile strengths due to low adhesion strength between particles, and low ductility due to low adhesion strength between particles and work hardening. Spark-plasma sintering (SPS) is a pressure-sintering technique that employs a large pulsed direct current. Compared to annealing heat treatment (AHT), SPS is expected to effectively improve the adhesion strength between particles in cold-sprayed metallic coatings. In order to investigate the effects of SPS, cold-sprayed Cu coatings were treated by both SPS and AHT under a wide range of temperatures. The microstructures and mechanical properties of the treated specimens were investigated primarily by scanning electron microscopy, electron backscatter diffraction analysis, hardness tests, and tensile tests. Despite comparable values for porosity, crystal grain size, plastic strain distribution, hardness, and yield stress, the tensile strength and ductility of the specimen treated by SPS at 400 C (SPS400) were significantly higher than those of the specimen treated by AHT at 450 C. Based on these results, it was determined that SPS treatment is more effective in improving the adhesion strength between the particles in cold-sprayed Cu coatings than AHT.