Porous copper coatings, which act as wicks for liquid transport, were fabricated using a flame spraying process. Copper and aluminum powders were fed independently into the spray torch and deposited on copper substrates to form a composite coating. The aluminum was subsequently removed using chemical leaching leaving a porous copper coating behind. Varying the feed rate of aluminum powder allowed the coating porosity to be controlled. Channels to enhance liquid flow were made in some of the porous copper coatings by placing pieces of aluminum wire mesh on the copper substrate before spraying. During spraying the sprayed powders passed through the mesh opening and created pyramid shaped arrays on the substrates. The groove width was controlled by using different wire mesh sizes. Coatings were made with porosity varying from 2 to 44, and groove width ranging from 0.16 to 0.53 mm. The capillary performance of the coatings was evaluated experimentally by measuring the rate-of-rise of ethanol in the coatings. The rate of rise increased with coating porosity, and decreased with groove width.
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