The Effect of Heat Treatment on the Microstructure and Thermal Conductivity of Cold-Sprayed GR-Cop-42

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PhD student Caleb Griffin, caleb.griffin@strath.ac.uk, University of Strathclyde; Dr. Titiana Marrocco, tiziana.marrocco@strath.ac.uk, Advanced Materials Research Laboratory; Dr. Calum Hicks, calum.hicks@strath.ac.uk, National Manufacturing Institue of Scotland; 

https://doi.org/10.53192/ITSC2026527

GR-Cop-42 is a copper-based alloy developed for high-heat-flux combustion chamber components, it has high thermal conductivity and retains tensile strength at elevated temperatures. Additive manufacturing of GR-Cop-42 via laser powder bed fusion has found several limitations. Cold spray additive manufacturing offers a solid-state alternative; however, the thermal properties of cold sprayed GR-Cop-42 have not yet been explored to the same extent as laser powder bed fusion. In this study, GR-Cop-42 was deposited by high-pressure cold spray and then heat-treated in both oxidising and inert atmospheres. The feedstock powder, as-sprayed and heat-treated deposits were microstructurally assessed using x-ray diffraction, electron microscopy and quantitative image analysis. Thermal conductivity was derived from laser flash and simultaneous thermal analysis. Heat treatment in an inert argon atmosphere resulted in the highest thermal conductivity across the combustion chamber operating temperature range, exceeding values reported for laser powder bed fusion and were more comparable to wrought. The results of this study demonstrate cold spray combined with appropriate post-processing treatment as a viable manufacturing route for high-heat-flux GR-Cop-42 components.

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March 2026

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