LAUSR

Abstract This paper examines a series of Al-Cu binary alloy coatings, ranging from 2 to 5 weight percent copper, produced using low-pressure cold spray (CS) deposition with helium as the carrier gas. Binary Al-Cu alloy feedstock powder was produced through inert gas atomization and was sprayed over a variety of temperatures and pressures. Using helium gas, this set of Al-Cu alloys was successfully deposited as high-density coatings. Raising the carrier gas pressure increased the particle velocity and deposition efficiency (DE) in the case of spraying the Al-5 wt.% Cu powders. A clear composite deformation structure was formed in all coatings with clear prior particle centers surrounded by severely deformed regions with ultrafine grains. Microstructural deformation generated by the CS process produced a weak but clear <110> fiber texture for both Al-2 wt.% Cu and Al-5 wt.% Cu coatings. The copper content of the feedstock powder directly influenced the coating hardness and porosity, while having no systematic effect on the DE.