Stored strain energy-driven interatomic diffusion in immiscible Multi-metal composites via cold spray

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Dr. Pengfei Yu, yup3@tcd.ie, Trinity College Dublin; Dr. Jiangfeng Wang, Dr. Rocco Lupoi, 

https://doi.org/10.53192/ITSC2026565

Multi-metal composites combine distinct metallic components through strong interfacial bonding, harnessing unique properties beneficial in electronics, aerospace, and nuclear applications. However, immiscible metal systems, such as tantalum (Ta) and silver (Ag), are inherently challenging to bond due to positive mixing enthalpies. Conventional bonding methods, including explosive welding and chemical vapor deposition, lack flexibility and economic viability. Here, cold spray—a solid-state deposition technique utilizing high-velocity particle impact—is employed to fabricate immiscible Ta-Ag composites. To overcome limitations from weak metallurgical bonding, post-spray heat treatments are introduced, resulting in significant enhancement of mechanical properties through optimized interfacial bonding. Critically, advanced microstructural characterization coupled with thermodynamic analysis reveals that stored strain energy from particle deformation drives interatomic diffusion, establishing robust metallurgical bonds between immiscible metals. These insights elucidate the mechanism behind interfacial bonding evolution, providing valuable guidelines applicable beyond cold spray to broader composite fabrication technologies.

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Erscheinungsdatum

March 2026

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