Journal of Thermal Spray Technology

, Volume 27, Issue 4, pp 624–640 | Cite as

Novel Method of Aluminum to Copper Bonding by Cold Spray

  • Si-Lin Fu
  • Cheng-Xin Li
  • Ying-Kang Wei
  • Xiao-Tao Luo
  • Guan-Jun Yang
  • Chang-Jiu Li
  • Jing-Long Li
Peer Reviewed


Cold spray bonding (CSB) has been proposed as a new method for joining aluminum and copper. At high speeds, solid Al particles impacted the groove between the two substrates to form a bond between Al and Cu. Compared to traditional welding technologies, CSB does not form distinct intermetallic compounds. Large stainless steel particles were introduced into the spray powders as in situ shot peen particles to create a dense Al deposit and to improve the bond strength of joints. It was discovered that introducing shot peen particles significantly improved the flattening ratio of the deposited Al particles. Increasing the proportion of shot peen particles from 0 to 70 vol.% decreased the porosity of the deposits from 12.4 to 0.2%, while the shear strength of joints significantly increased. The tensile test results of the Al-Cu joints demonstrated that cracks were initiated at the interface between the Al and the deposit. The average tensile strength was 71.4 MPa and could reach 81% of the tensile strength of pure Al.


cold spraying dissimilar metal joint in situ shot peening mechanical property microstructure 



This research was supported by the National Natural Science Foundation of China (No. 51761145108).


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Copyright information

© ASM International 2018

Authors and Affiliations

  • Si-Lin Fu
    • 1
  • Cheng-Xin Li
    • 1
  • Ying-Kang Wei
    • 1
  • Xiao-Tao Luo
    • 1
  • Guan-Jun Yang
    • 1
  • Chang-Jiu Li
    • 1
  • Jing-Long Li
    • 2
  1. 1.School of Materials Science and EngineeringXi’an Jiaotong UniversityXi’anChina
  2. 2.School of Materials Science and EngineeringNorthwestern Polytechnical UniversityXi’anChina

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