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研究生: 魏輔均
Wei, Fu-Jun
論文名稱: 銅冷噴塗製程及影響其機械性質因素之探討
Understanding of Cold-Spray Process and Factors affecting Mechanical Properties of Cold-Sprayed Cu Coatings
指導教授: 方冠榮
Fung, Kuan-Zong
學位類別: 博士
Doctor
系所名稱: 工學院 - 材料科學及工程學系
Department of Materials Science and Engineering
論文出版年: 2025
畢業學年度: 113
語文別: 英文
論文頁數: 99
中文關鍵詞: 冷噴塗銅塗層鍵結強度熱管理熱處理
外文關鍵詞: cold spray, copper coatings, bonding strength, thermal management, heat treatment
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  • 中文摘要1 ABSTRACT4 致謝8 List of Tables9 List of Figures10 Abbreviations16 Chapter 1 Introduction17 1.1 Historical Development of Thermal Management Solutions17 1.1.1 Rise of Direct Liquid Cooling17 1.1.2 DLC System Design and the Need for Solderable Coatings18 1.2 Copper as the Solderable Coating Material for Aluminum Cold Plates19 1.3 Comparison of Solderable Copper Coating Technologies20 1.3.1 Overview of Copper Coating Technologies20 1.3.1.1 Electroplating20 1.3.1.2 Thermal Spray20 1.3.1.3 Cold Spray21 1.3.2 Comparative Analysis of Copper Coating Technologies21 1.4 Cold Spray Overview24 1.4.1 Historical Background24 1.4.2 Main components of Cold Spray Systems25 1.4.2.1 Gas Pressure Controller26 1.4.2.2 Powder Feeder26 1.4.2.3 Gas Heater26 1.4.2.4 De Laval nozzle27 1.4.3 Bonding Mechanism of Cold Spray Deposition28 1.4.3.1 Energy Conversion28 1.4.3.2 Adiabatic Shear Instability29 1.4.3.3 Critical Velocity30 1.4.3.4 Mechanical Interlocking33 1.4.3.5 Metallurgical Bonding33 1.4.4 Stages of Coating Formation in Cold Spray34 1.4.4.1 Particle Acceleration34 1.4.4.2 Particle Impact and Deformation34 1.4.4.3 Breaking of Oxide Layers34 1.4.4.4 Formation of the First Layer34 1.4.4.5 Build-Up of Successive Layers34 1.4.5 Key Factors Influencing Cold Sprayed Coating Properties35 1.4.5.1 Process Gas Selection35 1.4.5.2 Temperature and Pressure of Process Gas35 1.4.5.3 Powder Characteristics36 1.4.5.4 Substrate Characteristics36 1.4.5.5 Stand-off distance36 1.4.6 Advantages and Limitations of Cold Spray Technology37 1.4.6.1 Advantages37 1.4.6.2 Limitations38 1.4.7 Industrial Applications39 1.5 Copper Powders from Different Manufacturing Methods41 1.5.1 Electrolytic Copper Powder41 1.5.2 Gas-Assisted Water Atomization Copper Powder42 1.5.3 Inert-Gas Atomization Copper Powder43 1.6 Review of Microstructural Properties of Cold-Sprayed Copper Coatings44 1.6.1 Grain Deformation and Fragmentation Mechanisms44 1.6.2 Misorientation and Strain Distribution Analysis45 1.6.3 Bonding Mechanisms Between Particles and Substrate45 1.6.4 Summary and Research Outlook46 Chapter 2 Motivation and Objectives47 Chapter 3 Experimental Procedure49 3.1 Materials and Cold Spray Parameters49 3.1.1 Feedstock Powders49 3.1.2 Specification of Substrate Materials49 3.1.3 Condition and Parameters of Cold Spray Process49 3.2 EBSD Sample Preparation and Characterization Methods50 3.3 Procedure of Bonding Strength Test51 3.4 Procedure of Experiment I: Study on the Effects of Powder Characteristics and Annealing in Cold Spray Processing52 3.5 Procedure of Experiment II: To investigate the Influence of Pre-Annealed Powders on Cold Spray Behavior55 Chapter 4 Experimental Result and Discussion57 4.1 Experiment I: Study on the Effects of Powder Characteristics and Annealing in Cold Spray Processing57 4.1.1 Characteristics of As-Received Copper Powders57 4.1.2 Characteristics of As-sprayed Copper Coatings62 4.1.3 Characteristics of Annealed Copper Coatings69 4.1.4 Summary72 4.1.4.1 As-sprayed Coating Behavior72 4.1.4.2 Post-Annealing Microstructural Recovery73 4.1.4.3 Feedstock Powder Selection Implications73 4.2 Experiment II: To investigate the Influence of Pre-Annealed Powders on Cold Spray Behavior74 4.2.1 Characteristics of As-received Copper Powders74 4.2.2 Characteristics of As-sprayed Copper Coatings77 4.2.3 Characteristics of Annealed Copper Powders81 4.2.4 Characteristics of As-sprayed Coatings from Annealed Copper Powders82 4.2.5 Summary 86 Chapter 5 Conclusion88 REFERENCES90

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