Cold-sprayed CuCrZr coating offers interesting multifunctional properties with a combination of high mechanical property, good thermal stability and substantial deposition thickness. Despite these advantages, the incorporation of solid solution elements and the deposit’s unique microstructure often result in suboptimal heat transfer capabilities. This study delved into the thermal conductivity of cold-sprayed CuCrZr coatings over a temperature range from room temperature to 600 °C. Furthermore, it quantitatively analyzed their microstructural evolution post-thermal testing and its correlation with thermal properties, employing techniques such as FESEM, EBSD, TEM, and XRD. Findings indicate the CuCrZr coating exhibits significant thermal sensitivity, with conductivity increasing from 65.83±1.79 W/(m∙K) at 25 °C to 198.42±0.63 W/(m∙K) at 600 °C. The annealing effect during thermal testing significantly enhances the coatings’ room temperature thermal properties, chiefly through the enhancement of interparticle metallurgical bonding, grain enlargement, solid solution precipitation, and a reduction in dislocation density. The thermal conduction across the coating/substrate interface is intricately influenced by the interplay between electrons and phonons, with impediments at the interface becoming markedly pronounced beyond 300 °C. The investigation pinpointed interparticle interfaces as the predominant barriers to heat transfer, contributing to 73.77 % of the total resistance. Meanwhile, the effects of solid solution elements, grain boundaries, and dislocations on thermal conductivity were comparatively minor, contributing 9.36 %, 1.04 %, and 0.44 %, respectively. However, it is also noted that the annealing effect can induce the coalescence of microcracks into pores and promote the precipitation or oxidation of Cr at the interfaces, which, in turn, limits the potential for further enhancements in thermal conductivity.
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