Additive manufacturing of Cu-Ta and Cu-W immiscible nanocomposites by cold spraying solid-state deposition

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Doctor / Professor Xiao-Tao Luo, luoxiaotao@mail.xjtu.edu.cn; Bai-Yao Zhao, 1447844343@qq.com; Master Fang-Yuan Liu, 1755600589@qq.com; Doctor/Professor Chang-Jiu Li, licj@mail.xjtu.edu.cn; 

https://doi.org/10.53192/ITSC2026596

Immiscible metallic nanocomposites show great promise for nuclear applications because of their outstanding radiation resistance. However, conventional melting-based additive manufacturing methods struggle with these materials due to large differences in melting points and densities between components. This study presents a breakthrough in fabricating Cu-Ta and Cu-W nanocomposites through cold spray additive manufacturing using mechanically milled powders. After 32 h of ball milling, both Cu-Ta and Cu-W powders developed nanostructures. At optimized spray parameters, dense deposits with low porosities (1.73% for Cu-Ta, 1.65% for Cu-W) can be deposited. The resulting nanocomposites feature unique microstructures where nano-sized Ta and W particles are discontinuously distributed in a nanocrystalline Cu matrix. The high-velocity impact during deposition transforms continuous Ta networks into chrysanthemum-like patterns and aligned W nanoparticles through shear deformation. These microstructures achieved remarkable phase boundary densities (0.073 nm⁻¹ for Ta/Cu, 0.159 nm⁻¹ for W/Cu), 40-170% higher than comparable nano-multilayer films. The discontinuous phase distribution also improved thermal stability by blocking diffusion, allowing the Cu-W nanocomposite to maintain its nanostructure after 2 hours at 800°C. This work demonstrates cold spraying as an effective method for producing immiscible nanocomposites.

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Erscheinungsdatum

March 2026

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