Abstract

This thesis explores the deposition of copper coatings using Cold Spray (CS) and High-Velocity Air Fuel (HVAF) technologies, focusing on minimizing oxide formation to preserve copper’s desirable properties for high-performance applications in aerospace, automotive, and energy industries. Copper is highly valued for its excellent thermal and electrical conductivity, but oxide formation can degrade its performance, leading to reduced conductivity, corrosion resistance, and mechanical integrity. Both CS and HVAF techniques, which rely on high particle velocities, are evaluated for their ability to mitigate oxidation and optimize coating quality. The study examines the impact of various spray parameters, such as pressure, temperature, standoff distance, and feedstock characteristics, on the resulting microstructure, oxide content, and surface roughness of the coatings. In addition to optimizing spray parameters, the thesis investigates the use of N-heterocyclic carbene (NHC) coatings on copper powders to further reduce oxidation during handling and deposition. The NHC treatment forms a self-assembled protective monolayer that reduces native oxides and enhances coating adhesion and corrosion resistance. Experimental results confirm the successful formation of the NHC monolayer through XPS and LDI analysis, and the optimal treatment protocol is identified. The findings demonstrate that both Cold Spray and HVAF can produce high-quality copper coatings with minimal oxide formation when carefully optimized, and NHC-treated copper powders further improve corrosion resistance and prevent oxidation. This research offers valuable insights into enhancing the longevity and performance of copper coatings, potentially reducing maintenance costs and extending service life in industries facing corrosive or high-temperature conditions.