Enhanced arc erosion resistance via constructing W particle network structure in cold sprayed CuCrZr–W coating: Implication for electromagnetic launching system

In electromagnetic launching systems, arc erosion of rail material, such as Al2O3 dispersion-strengthened copper (ODS-Cu), remains a critical unresolved issue. Here, we report a cold-sprayed CuCrZr–W coating on ODS-Cu exhibiting enhanced arc erosion resistance. The coating was fabricated using a bimodal powder mixture comprising coarse CuCrZr and fine W particles, resulting in a dense structure with an embedded networks of fine W particles along intersplat boundaries. Compared to the ODS-Cu substrate, the CuCrZr–W coating displays superior arc erosion resistance, as evidenced by the reduced arc erosion area and depth, shorter arc duration, lower wielding force, and limited molten Al adhesion during arcing tests. The enhanced performance is attributed to a high density of W/CuCrZr interfaces that effectively disperse arcs, the W particle network that alters the flow path of molten Cu, lowering splashing and evaporation. This work provides valuable insights into developing high-performance, arc erosion-resistant coatings for applications where safeguarding against arc erosion is paramount.