Flame spraying copper to aluminum
03-16-2015, 07:31 PM,
#1
Flame spraying copper to aluminum
Hello everyone,

I'm looking for some advice about getting better adhesion with my copper spray. I'm flame spraying a 100% copper powder onto an aluminum plate that has been sandblasted with a #16 grit at 125 psi. After spraying, I am soldering copper tubes to the copper layer and, in testing the bond strength, am able to pull off the tube with solder and copper spray layer attached. Is there something I'm missing? Any recommendations? Thanks
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03-17-2015, 08:28 AM,
#2
RE: Flame spraying copper to aluminum
(03-16-2015, 07:31 PM)Steamhammer Wrote: Hello everyone,

I'm looking for some advice about getting better adhesion with my copper spray. I'm flame spraying a 100% copper powder onto an aluminum plate that has been sandblasted with a #16 grit at 125 psi. After spraying, I am soldering copper tubes to the copper layer and, in testing the bond strength, am able to pull off the tube with solder and copper spray layer attached. Is there something I'm missing? Any recommendations? Thanks

Hi Steamhammer,

Flame spraying can not get a good copper coating, especially on aluminum. The fact that the surface of the aluminum and of copper particles are oxidized and metallic bond between the coating and the substrate can not be formed. Furthermore, flame spraying can not give the required speed of copper particles to form a dense coating.

For quality copper coating on aluminum is only suitable methods of cold spray and HVAF.


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03-23-2015, 05:32 PM,
#3
RE: Flame spraying copper to aluminum
We have a lot of experience HVAF spraying copper onto aluminum substrates. Our customers have successfully machined the copper, and it does not peel off, even when the cutting tool penetrates the coating and starts removing the aluminum substrate.

As Vadim indicated, flame spray will not give you the results you want. Copper and aluminum oxidize very quickly, and that will interfere with the bond.

If you would like assistance with your project, you can contact me off-line.
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