Understanding the Antipathogenic Performance of Nanostructured and Conventional Copper Cold Spray Material Consolidations and Coated Surfaces

Antipathogenic Activity of Betainized Polyethyleneimine Sprays Without Toxicity

Background/Objectives: The design of alternative antipathogenic sprays has recently attracted much attention due to the limitations of existing formulations, such as toxicity and low and narrow efficacy. Polyethyleneimine (PEI) is a great antimicrobial polymer against a wide range of pathogens, but toxicity limits its use. Here, betainized PEI (B-PEI) was synthesized to decrease the toxicity of PEI and protonated with citric acid (CA), boric acid (BA), and HCl to improve antimicrobial activity. Methods: Cytotoxicity of the PEI-based solutions was determined on L929 fibroblast cells. Antibacterial/fungal activity of PEI-based antipathogenic sprays was investigated by microtiter and disc diffusion assays, in addition to bacterial viability and adhesion % of common bacteria and fungi on the PEI-treated masks. Furthermore, the antiviral effect of the PEI-based solutions was determined against SARS-CoV-2 virus. Results: The biosafe concentration of PEI was determined as 1 μg/mL with 75 ± 11% cell viability, but B-PEI and its protonated forms had great biocompatibility even at 1000 μg/mL with more than 85% viability. The antibacterial/fungal effect of non-toxic B-PEI was improved by protonation with BA and HCl with 2.5-10 mg/mL minimum bactericidal/fungicidal concentrations (MBCs/MFCs). Bacterial/fungal viability and adhesion on the mask was almost eliminated by using 50 μL with 5-10 mg/mL of B-PEI-BA. Both protonated bare and betainized PEI show potent antiviral activity against SARS-CoV-2 virus. Conclusions: The toxicity of PEI was overcome by using betainized forms of PEI (B-PEI). Furthermore, the antimicrobial and antiviral efficacy of PEI and B-PEI was improved by protonation with CA, BA, and HCl of amine groups on B-PEI. B-PEI-BA spray solution has great potential as an antipathogenic spray with broad-spectrum antimicrobial potency against harmful bacteria, fungi, and viruses without any toxicity.

Enhancing anti-adhesion properties by designing microstructure - the microscopy and spectroscopy study of the intercellular bacterial response

This study is the first one that investigates in detail the bacterial intercellular response to the high density of crystallographic defects including vacancies created in Cu by high pressure torsion. To this aim, samples were deformed by high pressure torsion and afterward, their antibacterial properties against Staphylococcus aureus were analyzed in adhesion tests. As a reference an annealed sample was applied. To avoid the influence of surface roughness, specially elaborated conditions for surface preparation were employed, which do not introduce defects and assure comparable surface roughness. The analysis of the chemical composition and thickness of passive layers by X-ray photoelectron spectroscopy showed that they were comparable for nanostructured and micrograined samples, consisting of Cu2O and CuO, and a thickness of 6 nm. The interface bacterium-substrate was prepared by a focused ion beam and further analyzed by scanning transmission electron microscopy and energy dispersive spectroscopy. High pressure torsion processed Cu shows enhanced anti-adhesion properties while in contact with S. aureus than micrograined Cu. There is a linear correlation between luminous intensity and grain size-0.5. The bacterial intercellular defence mechanism includes the creation of Cu2O nanoparticles and the increased concentration of sulphur-rich compounds near these nanoparticles.

Application of Mass Finishing for Surface Modification of Copper Cold Sprayed Material Consolidations

The surface roughness of additively manufactured (AM) components can have deleterious effects on the properties of the final part, such as corrosion resistance and fatigue life. Modification of the surface finish or parts produced by AM processes, such as cold spray, through methods such as mass finishing, can help to mitigate some of these issues. In this work, the surface evolution of as-produced copper cold sprayed material consolidations was studied through mass finishing. Three different copper powders attained by different production methods and of different sizes were used as feedstock. The surface topography of the cold spray deposits was measured as a function of the mass finishing time for the three copper cold spray samples and analyzed in terms of relative area and complexity, revealing an inverse correlation relating material removal rate and hardness/strength of the cold sprayed deposits. The material removal rate was also affected by the quality of the cold spray deposition, as defined by deposition efficiency (DE). Large initial drops in relative area and complexity are also likely due to the removal of loosely bonded powders at the start of mass finishing. Based on this study, the cold spray parameters that affect the rate of mass finishing have been explored.

Biofilm Inhibition and Antiviral Response of Cold Sprayed and Shot Peened Copper Surfaces: Effect of Surface Morphology and Microstructure

Antibacterial properties of copper against planktonic bacteria population are affected by surface microstructure and topography. However, copper interactions with bacteria in a biofilm state are less studied. This work aims at better understanding the difference in biofilm inhibition of bulk, cold-sprayed, and shot-peened copper surfaces and gaining further insights on the underlying mechanisms using optical and scanning electron microscopy to investigate the topography and microstructure of the surfaces. The biofilm inhibition ability is reported for all surfaces. Results show that the biofilm inhibition performance of cold sprayed copper, while initially better, decreases with time and results in an almost identical performance than as-received copper after 18h incubation time. The shot-peened samples with a rough and ultrafine microstructure demonstrated an enhanced biofilm control, especially at 18 hr. The biofilm control mechanisms were explained by the diffusion rates and concentration of copper ions and the interaction between these ions and the biofilm, while surface topography plays a role in the bacteria attachment at the early planktonic state. Furthermore, the data suggest that surface topography plays a key role in antiviral activity of the materials tested, with a smooth surface being the most efficient.

Graphical Abstract

On the emergence of antibacterial and antiviral copper cold spray coatings

In this literature review, the antipathogenic properties and contact-mediated antibacterial and antiviral performance of copper cold spray surfaces are assessed and compared with alternative antimicrobial materials that are able to kill and/or inactivate infectious agents via direct contact. Discussion is also provided concerning the suitability of copper cold spray material consolidations as biocidal and viricidal surfaces that retain long-term functionality as a preventative measure against fomite transmission of pathogenic agents and hospital-acquired infections from contaminated high-touch surfaces. Numerable alternative antimicrobial coatings and surfaces that do not rely upon the oligodynamic action of copper are detailed. Given the ongoing need for recognition of said alternative antimicrobial materials by authoritative agencies, such as the U.S. Environmental Protection Agency, the relevant literature on non-copper-based antipathogenic coatings and surfaces are then described. Furthermore, a wide-ranging take on antipathogenic copper cold spray coatings are provided and consideration is given to the distinctive grain-boundary mediated copper ion diffusion pathways found in optimizable, highly deformed, copper cold spray material consolidations that enable pathogen inactivation on surfaces from direct contact. To conclude this literature review, analysis of how copper cold spray coatings can be employed as a preventative measure against COVID-19 was also presented in light of on-going debates surrounding SARS-CoV-2's non-primary, but non-negligible, secondary transmission pathway, and also presented in conjunction with the inevitability that future pathogens, which will be responsible for forthcoming global pandemics, may spread even more readily via fomite pathways too.

Antimicrobial Copper Cold Spray Coatings and SARS-CoV-2 Surface Inactivation

This article contextualizes how the antimicrobial properties and antipathogenic contact killing/inactivating performance of copper cold spray surfaces and coatings and can be extended to the COVID-19 pandemic as a preventative measure. Specifically, literature is reviewed in terms of how copper cold spray coatings can be applied to high-touch surfaces in biomedical as well as healthcare settings to prevent fomite transmission of SARS-CoV-2 through rapidly inactivating SARS-CoV-2 virions after contaminating a surface. The relevant literature on copper-based antipathogenic coatings and surfaces are then detailed. Particular attention is then given to the unique microstructurally-mediated pathway of copper ion diffusion associated with copper cold spray coatings that enable fomite inactivation.

Nanomechanical Characterization for Cold Spray: From Feedstock to Consolidated Material Properties

Cold gas-dynamic spray is a solid-state materials consolidation technology that has experienced successful adoption within the coatings, remanufacturing and repair sectors of the advanced manufacturing community. As of late, cold spray has also emerged as a high deposition rate metal additive manufacturing method for structural and nonstructural applications. As cold spray enjoys wider recognition and adoption, the demand for versatile, high-throughput and significant methods of particulate feedstock as well consolidated materials characterization has also become more notable. In order to address the interest for such an instrument, nanoindentation is presented herein as a viable means of achieving the desired mechanical characterization abilities. In this work, conventionally static nanoindentation testing using both Berkovich and spherical indenter tips, as well as nanoindentation using the continuous stiffness measurement mode of testing, will be applied to a range of powder-based feedstocks and cold sprayed materials.