Commercially available, high-purity (99.9%) spherical Ni and Al powders as well as mechanically crushed CuO powder (Buhan Chemical Technology in Shanghai, China) were used as raw materials. Figure 1 shows their scanning electron microscopy (SEM) morphology.
Fig. 1 SEM images of initial powders: (a) Al, (b) Ni, and (c) CuO
The mass ratio of Ni to Al was set to 7.5:1, while the CuO content in the mixed ternary powder was about 16 wt.%. Ni–Al–CuO ternary composite coating was deposited by cold spraying using a low-pressure cold-spraying system (KM-CDS3.2, Inovati Co., USA) with helium as propellant gas. Table 1 presents the main deposition parameters. For comparison, Ni–Al binary coating was also deposited using Ni and Al powders mechanically mixed at mass ratio of 7.5:1.
Table 1 Cold-spray process operating parameters
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