Fabrication and characterization of W-Cu composite coatings with different W contents by cold spraying

W-Cu composite coatings with different tungsten (W) contents were fabricated by cold spraying. The morphology and microstructure were studied using scanning electron microscopy (SEM), with W content and porosity of the final coatings being measured by an Image analysis software program equipped with SEM. Results showed that a dense coating with very low porosity, and free of impurity phase can be obtained by cold spraying. The porosity and thickness of the coatings decreased with the increasing of W content in the starting blend powders. The deposition efficiency of W was improved with the addition of soft particles. The wear behavior and possible bonding mechanisms of W-Cu composite coatings were also investigated.