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Comparative Evaluation of Cold-Sprayed and Electroplated Copper Coatings: Enhanced Performance Characteristics and an Alternative Copper Coating Approach
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DOI：10.1007/s11666-026-02294-3.png)
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Abstract
En 中文
To clarify performance differences between cold-sprayed copper coatings (CS-Cu) and electroplated copper coatings (EP-Cu), and optimize the cold spray process for efficient fabrication of high-performance Cu coatings, this study investigated the effects of spray gas temperature/pressure, spray distance, and gun traverse speed on the microstructure and properties of CS-Cu on AA6061 substrate via orthogonal experiments, and systematically compared the optimized CS-Cu with the EP-Cu. Optimization results showed that CS-Cu at specific parameters achieved optimal comprehensive performance, featuring low porosity, high hardness, and strong bonding strength. Microstructurally, CS-Cu was thicker and denser than EP-Cu, and was free of obvious interfacial. Mechanically, CS-Cu outperformed EP-Cu in elastic modulus and hardness. Wear tests revealed that CS-Cu had a lower steady-state friction coefficient and smaller wear volume (dominant abrasive wear), whereas EP-Cu exhibited inferior wear resistance and complex mechanisms due to weak interfacial bonding. CS-Cu also exhibited superior corrosion resistance, characterized by a self-corrosion current density of approximately 44% that of EP-Cu. In conclusion, optimized cold spray parameters produce dense, high-performance Cu coatings offering theoretical and experimental support for replacing electroplating in high-performance coating fabrication. This study proposes cold-sprayed copper (CS-Cu) as an eco-friendly alternative to conventional electroplated copper (EP-Cu). Optimized CS-Cu coatings show denser microstructure, stronger substrate adhesion, and higher hardness than EP-Cu. For the first time, this work identifies the superior tribological performance of CS-Cu with earlier running-in and more stable wear behavior. Electrochemical tests also reveal improved corrosion resistance and more stable passive films. These findings validate CS-Cu as a high-performance, environmentally benign substitute, providing a novel approach for advanced copper coating development.
Keywords:
AA6061 aluminum alloy
cold spray
copper coating
electroplating
microstructure and property
process optimization
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