In a groundbreaking development poised to reshape the energy sector, researchers have unveiled a novel approach to cold spray additive manufacturing (CSAM) that significantly enhances the strength and ductility of copper deposits. This innovation, detailed in a recent study published in *Materials & Design* (translated as *Materials & Design*), could revolutionize the production of critical components for power generation and transmission.
At the heart of this advancement is a unique bi-modal grain structure, where nanocrystalline grains envelop microcrystalline grains, creating a copper material with unprecedented mechanical properties. “This bi-modal structure is key,” explains lead author Tianqi Zhu from the Department of Mechanical, Manufacturing & Biomedical Engineering at Trinity College Dublin. “It combines the best of both worlds—high strength from the nanocrystalline regions and enhanced ductility from the microcrystalline grains.”
The research, spearheaded by Zhu, demonstrates that this novel structure achieves an ultimate tensile strength of 337 MPa and an elongation to failure of 16.2%, a remarkable feat in material science. The study’s in-situ tensile testing, coupled with Electron Backscatter Diffraction (EBSD), reveals that the material’s coordinated deformation mechanisms—grain growth in nanocrystalline regions and rotation in microcrystalline grains—enable strain accommodation and delay failure. As deformation progresses, the plastic deformation mechanism transitions to one dominated by dislocation nucleation and accumulation, leading to the fragmentation of nanocrystalline grains and further refinement of microcrystalline grains.
The implications for the energy sector are profound. Copper is a critical material in power generation, transmission, and distribution due to its excellent electrical conductivity and thermal properties. However, achieving the right balance between strength and ductility has been a longstanding challenge. This new approach to CSAM could enable the production of copper components that are not only stronger and more durable but also more efficient in conducting electricity, potentially leading to significant energy savings and reduced costs.
“This research opens up new possibilities for the design and manufacture of copper components in the energy sector,” says Zhu. “By optimizing the grain structure, we can tailor the mechanical properties of copper to meet the specific demands of various applications, from power generation to renewable energy systems.”
The study’s findings, published in *Materials & Design*, highlight the potential of bi-modal structured cold spray copper deposits to shape future developments in the field. As the energy sector continues to evolve, driven by the need for more efficient and sustainable solutions, this innovation could play a pivotal role in advancing the technology and infrastructure that power our world.
In an era where material science is at the forefront of technological innovation, this research stands as a testament to the power of interdisciplinary collaboration and the potential of additive manufacturing to transform traditional industries. As Zhu and his team continue to explore the possibilities of this novel approach, the energy sector can look forward to a future where stronger, more ductile, and more efficient copper components are the norm rather than the exception.