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The microstructure of the coating obtained by cold gas-dynamic spraying was investigated. A Cu-Al2O3-Zn powder blend was sprayed onto a copper substrate to restore a worn copper contact wire. The coating thickness was 1–2.5 mm. Mechanisms of coating formation are discussed on the basis of microstructure studies. The relationship between the microstructure and the properties of the coating such as adhesion strength and electrical conductivity is shown. Improved adhesion strength was achieved through substrate surface preprocessing with coarse Al2O3 particles.

Microstructural Studies of the Copper-Based Coating Obtained by Cold Gas-Dynamic Spraying for the Restoration of Worn-Out Contact Wires