A Review on Additive Manufacturing of Pure Copper

Jiang, Qi–Chuan; Zhang, Peilei; Yu, Zhishui; Shi, Haichuan; Wu, Di; Yan, Hua; Ye, Xin; Lu, Qinghua; Tian, Yingtao

doi:10.3390/coatings11060740

Cited by 93 publications

(42 citation statements)

References 129 publications

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“…Copper and copper alloys are widely utilised in industry because of their remarkable properties such as thermal, electrical and corrosion resistance [141]. The utilisation of this metal in AM has diverse applications in various sectors including electronics [142], aerospace [143], automotive [141], heat exchangers [143] and MEMs [142].…”

Section: Femtosecond Laser Sintering Of Coppermentioning

confidence: 99%

Femtosecond Laser-Based Additive Manufacturing: Current Status and Perspectives

Kaligar

Kumar

Ali

et al. 2022

QuBS

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The ever-growing interest in additive manufacturing (AM) is evidenced by its extensive utilisation to manufacture a broad spectrum of products across a range of industries such as defence, medical, aerospace, automotive, and electronics. Today, most laser-based AM is carried out by employing continuous-wave (CW) and long-pulsed lasers. The CW and long-pulsed lasers have the downside in that the thermal energy imparted by the laser diffuses around the irradiated spot and often leads to the creation of heat-affected zones (HAZs). Heat-affected zones may degrade the material strength by producing micro-cracks, porous structures and residual stresses. To address these issues, currently, attempts are being made to employ ultrafast laser sources, such as femtosecond (fs) lasers, in AM processes. Femtosecond lasers with pulse durations in the order of 10−15 s limit the destructive laser–material interaction and, thus, minimise the probability of the HAZs. This review summarises the current advancements in the field of femtosecond laser-based AM of metals and alloys. It also reports on the comparison of CW laser, nanosecond (ns)/picosecond (ps) lasers with fs laser-based AM in the context of heat-affected zones, substrate damage, microstructural changes and thermomechanical properties. To shed light on the principal mechanisms ruling the manufacturing processes, numerical predictions are discussed and compared with the experimental results. To the best of the authors’ knowledge, this review is the first of its kind to encompass the current status, challenges and opportunities of employing fs lasers in additive manufacturing.

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Section: Femtosecond Laser Sintering Of Coppermentioning

confidence: 99%

Femtosecond Laser-Based Additive Manufacturing: Current Status and Perspectives

Kaligar

Kumar

Ali

et al. 2022

QuBS

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“…The powders processed by L-PBF must have a good absorbance at the wavelength of 1064-1070 nm. Pure copper and aluminum are characterized by a low laser absorbance at 1070 nm [41,42,94], as shown in Figure 1 below. characterized by erosive and abrasive-based wear processes.…”

Section: Powders Absorptancementioning

confidence: 99%

“…The powders processed by L-PBF must have a good absorbance at the wavelength of 1064-1070 nm. Pure copper and aluminum are characterized by a low laser absorbance at 1070 nm [41,42,94], as shown in Figure 1 below. Figure 1 reports the absorbance of stainless steel 304, titanium, aluminum, and copper as function of the wavelength.…”

Section: Powders Absorptancementioning

confidence: 99%

“…L-PBF is a layer-by-layer process where a laser beam is applied to melt the metal powders selectively; the molten layer then solidifies at a high cooling rate [36][37][38][39][40]. Adopting a laser source implies using metal powders characterized by a proper laser absorptivity [41,42]. Poor absorbance causes many defects such as pores, low-quality surfaces, and un-melted powder in the 3D-printed parts [41,[43][44][45][46].…”

Section: Introductionmentioning

confidence: 99%

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Coated Metal Powders for Laser Powder Bed Fusion (L-PBF) Processing: A Review

Bidulský¹,

Gobber

Bidulská

et al. 2021

Metals

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In the last years, functionalized powders are becoming of increasing interest in additive manufacturing (particularly in laser powder bed fusion processing, L-PBF), due to their improved flowability and enhanced processability, particularly in terms of laser absorbance. Functionalized powders may also provide higher final mechanical or physical properties in the manufactured parts, like an increased hardness, a higher tensile strength, and density levels close to theoretical. Coatings represent a possible interesting approach for powders’ functionalizing. Different coating methods have been studied in the past years, either mechanical or non-mechanical. This work aims to present an overview of the currently obtained coated powders, analyzing in detail the processes adopted for their production, the processability of the coated systems, and the mechanical and physical properties of the final parts obtained by using L-PBF for the powders processing.

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“…Thus, the energy coupling into the pure copper powder bed increases, and defect-free processing is possible by using a green laser source [9,10]. At the same time, the L-PBF technology is well-placed for the required mechanical complexity and offers significant design and optimisation freedom to meet the requirements for the RFQ (i.e., integrated cooling channels) that cannot be achieved by the mentioned nozzle technology [9][10][11][12][13].…”

Section: Am Technology and Challengesmentioning

confidence: 99%

First Proof-of-Concept Prototype of an Additive Manufactured Radio Frequency Quadrupole

et al. 2021

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Continuous developments in additive manufacturing (AM) technology are opening up opportunities in novel machining, and improving design alternatives for modern particle accelerator components. One of the most critical, complex, and delicate accelerator elements to manufacture and assemble is the radio frequency quadrupole (RFQ) linear accelerator, which is used as an injector for all large modern proton and ion accelerator systems. For this reason, the RFQ has been selected by a wide European collaboration participating in the AM developments of the I.FAST (Innovation Fostering in Accelerator Science and Technology) Horizon 2020 project. The RFQ is as an excellent candidate to show how sophisticated pure copper accelerator components can be manufactured by AM and how their functionalities can be boosted by this evolving technology. To show the feasibility of the AM process, a prototype RFQ section has been designed, corresponding to one-quarter of a 750 MHz 4-vane RFQ, which was optimised for production with state-of-the-art laser powder bed fusion (L-PBF) technology, and then manufactured in pure copper. To the best of the authors’ knowledge, this is the first RFQ section manufactured in the world by AM. Subsequently, geometrical precision and surface roughness of the prototype were measured. The results obtained are encouraging and confirm the feasibility of AM manufactured high-tech accelerator components. It has been also confirmed that the RFQ geometry, particularly the critical electrode modulation and the complex cooling channels, can be successfully realised thanks to the opportunities provided by the AM technology. Further prototypes will aim to improve surface roughness and to test vacuum properties. In parallel, laboratory measurements will start to test and improve the voltage holding properties of AM manufactured electrode samples.

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A Review on Additive Manufacturing of Pure Copper

Cited by 93 publications

References 129 publications

Femtosecond Laser-Based Additive Manufacturing: Current Status and Perspectives

Femtosecond Laser-Based Additive Manufacturing: Current Status and Perspectives

Coated Metal Powders for Laser Powder Bed Fusion (L-PBF) Processing: A Review

First Proof-of-Concept Prototype of an Additive Manufactured Radio Frequency Quadrupole

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