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Anisotropic Electrical Conductivity of Copper Coatings Deposited by HVOF


 Copper coatings were deposited on ferrous substrates by utilizing high-velocity oxy-fuel spraying (HVOF). Three different coating process parameters have been used in order to optimise the required electrical characteristics. Microstructure and phase formation in the coatings were analyzed by scanning electron microscope (SEM), X-ray diffraction (XRD), and oxygen analyzer (ELTRA). Electrical resistivity of coatings was measured in-plane and through-thickness using the four-contact method. Results shown that dense coatings with high purity and low level of porosity are required to achieve high electrical conductivity. The coatings exhibited an anisotropic electrical resistivity due to the nature of the thermal spray coating microstructure. Microstructural evaluation shown that individual splats morphology and splats interfaces play important roles in the electrical conductivity.