Cold Spray Additive Manufacturing of Copper Alloys: Electrical and Mechanical Performance for High Magnetic Field Production

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Rajat Kawalkar, rajatkawalkar123@gmail.com, Université de technologie de Belfort Montbéliard (UTBM) Belfort; Ralph Seulin, ralph.seulin@utbm.fr, Université Bourgogne Europe, CNRS, Laboratoire Interdisciplinaire Carnot de Bourgogne ICB UMR 6303, 21000 Dijon, France; Christophe Verdy, christophe.verdy@utbm.fr, Université Marie et Louis Pasteur, UTBM, CNRS, Laboratoire Interdisciplinaire Carnot de Bourgogne ICB UMR 6303, 90010 Belfort, France; Francois Debray, francois.debray@lncmi.cnrs.fr, Laboratoire National des Champs Magnétiques Intenses (LNCMI – CNRS-UPS-INSA-UJF), 25 Rue des Martyrs, 38042 Grenoble, France; Sihao.Deng, sihao.deng@utbm.fr, Université Marie et Louis Pasteur, UTBM, CNRS, Laboratoire Interdisciplinaire Carnot de Bourgogne ICB UMR 6303, 90010 Belfort, France; 

In this study, the comparison of properties between pure copper classical tubes is made with cold spray under helium and nitrogen and CSAM made with nitrogen. Various material characterizations are employed to evaluate the quality of the spray-coated samples. Pure copper is investigated first to establish a baseline for assessing the influence of different cold spray strategies and carrier gas before extending the approach to copper alloys. This work provides a reference framework for comparing different cold spray processing routes for pure copper. Future work will focus on extending this comparison to CSAM-fabricated pure copper tubes produced using helium as the carrier gas.

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March 2026

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