影响冷喷涂粒子沉积的关键因素：粉末表面氧化综述

doi:10.11900/0412.1961.2025.00087

金属学报

2026, Vol. 62

Issue (1): 17-28 DOI: 10.11900/0412.1961.2025.00087

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影响冷喷涂粒子沉积的关键因素：粉末表面氧化综述

李文亚¹(

), 杨景文¹, 雒晓涛², 殷硕³, 徐雅欣¹

1 西北工业大学材料学院凝固技术全国重点实验室陕西省摩擦焊接工程技术重点实验室西安 710072
2 西安交通大学材料科学与工程学院西安 710049
3 School of Mechanical Manufacturing and Biomedical Engineering, Trinity University Dublin, D02PN40, Ireland

Key Factors Affecting Cold Spray Particle Deposition: A Review of Powder Surface Oxidation

LI Wenya¹(

), YANG Jingwen¹, LUO Xiaotao², YIN Shuo³, XU Yaxin¹

1 Shaanxi Provincial Key Laboratory of Friction Welding Engineering Technology, State Key Laboratory of Solidification Technology, School of Materials Science and Engineering, Northwestern Polytechnical University, Xi'an 710072, China
2 School of Materials Science and Engineering, Xi'an Jiaotong University, Xi'an 710049, China
3 School of Mechanical Manufacturing and Biomedical Engineering, Trinity University Dublin, D02PN40, Ireland

引用本文:

李文亚, 杨景文, 雒晓涛, 殷硕, 徐雅欣. 影响冷喷涂粒子沉积的关键因素：粉末表面氧化综述[J]. 金属学报, 2026, 62(1): 17-28.
Wenya LI, Jingwen YANG, Xiaotao LUO, Shuo YIN, Yaxin XU. Key Factors Affecting Cold Spray Particle Deposition: A Review of Powder Surface Oxidation[J]. Acta Metall Sin, 2026, 62(1): 17-28.

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摘要:

冷喷涂技术因具有低温固态沉积特性，在高性能金属或金属基复合涂层制备、修复及增材制造领域已有重要应用。然而，原始喷涂粉末的表面氧化状态对冷喷涂粒子沉积过程及所制备涂层或沉积体的微观组织、界面结合质量和力学性能具有重要影响。一般来说，粒子表面氧化膜的存在增加了粉末的临界沉积速率，降低了粒子塑性变形能力，并在界面处形成未结合区或脆性夹杂，从而显著影响粉末的沉积效率和沉积体的力学性能。然而，在特定条件下，粉末表面的氧化膜经过碰撞作用而破碎，不连续的氧化膜均匀分布在涂层中，通过弥散强化能够提高涂层的硬度。本文主要综述了粉末表面氧化膜在喷涂沉积过程中的破碎行为及其对涂层微观组织和性能的影响，重点探讨了氧化膜对界面结合、涂层组织及性能的影响机制。此外，本文还提出了高强塑性沉积体对粉末低O含量的严格要求，为优化冷喷涂材料性能提供理论指导。最后，对粉末表面氧化膜在冷喷涂增材制造中的影响及未来研究方向进行了展望。

关键词 ：冷喷涂, 冷喷涂增材制造, 氧化膜, O含量, 粒子变形, 界面结合

Abstract：

Cold spraying (CS), recognized for its solid-state deposition characteristics, holds significant potential for the fabrication of high-performance coatings, the repair of damaged components, and the additive manufacturing of metals and metal matrix composites. However, oxide films present on the surfaces of powder particles exert a profound impact on particle deformation during CS, as well as on the interfacial microstructure, bonding quality, and mechanical properties of the resulting coatings or deposits. The presence of oxide films increases the critical deposition velocity, reduces the plastic deformation capacity of particles, and promotes the formation of unbonded regions or brittle inclusions at interfaces, thereby compromising deposition efficiency and mechanical integrity. Nevertheless, under specific conditions, the oxide film on the powder surface can be fractured by particle collisions, and the resulting discontinuous oxide film may become evenly distributed, potentially contributing to the dispersion strengthening and enhancing the hardness of the coating. This study presents a comprehensive review of the deformation behavior of oxide films during the CS process and their influence on coating microstructure and properties, with particular focus on the mechanism where how oxide film influences interfacial bonding, coating microstructure and performance. Furthermore, the study discusses the importance of minimizing oxygen content in feedstock powders to achieve high-strength and high-ductility deposits, providing theoretical guidance for optimizing coating performance. Finally, the role of oxide films in CS-based additive manufacturing is explored, and prospective research directions are outlined.

Key words： cold spraying cold spray additive manufacturing oxide film oxygen content particle deformation interfacial bonding

收稿日期: 2025-03-27

ZTFLH:

TG147

基金资助:国家自然科学基金项目(52061135101);陕西省重点科技创新团队项目(2024RS-CXTD-20)

通讯作者: 李文亚，liwy@nwpu.edu.cn，主要从事冷喷涂与摩擦焊接工艺基础及应用研究

作者简介: 李文亚，男，1976年生，教授，博士

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https://www.ams.org.cn/CN/10.11900/0412.1961.2025.00087 或 https://www.ams.org.cn/CN/Y2026/V62/I1/17

图1 冷喷涂技术原理示意图[13]

图2 冷喷涂粒子表面氧化膜破碎-结合过程示意图[27]

图3 不同粉末的临界沉积速率与粉末O含量的关系[5]

图4 利用人工氧化的铜粉冷喷涂制备铜涂层截面组织腐蚀前后的OM像[26]

图5 不同O含量镍粉末冷喷涂制备涂层截面形貌的OM像[36]

图6 不同O含量镍粉末冷喷涂制备涂层截面形貌的EBSD表征[36]

图7 不同O含量的镍粉冷喷涂制备涂层的硬度[36]

图8 储存态与酸洗后铜粉冷喷涂制备沉积体的拉伸力学性能[37]

图9 不同O含量铜粉冷喷涂制备沉积体的导电性[23]

图10 不同O含量铜粉沉积效率及不同粉末沉积效率下涂层截面组织形貌[23]

图11 冷喷涂增材制造铜沉积体的拉伸力学性能[39]

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