Additive manufacturing of copper alloys: Influence of process parameters and alloying elements

Tiberto, Dario; Klotz, Ulrich; Held, Franz; Wolf, Gerhard

doi:10.1080/02670836.2019.1600840

Cited by 28 publications

(13 citation statements)

References 16 publications

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“…Laser spot sizes less than 40 µm are not common in the L-PBF process due to the limitations with the currently existing machines. However, there seems to be no limitation in decreasing the powder layer thickness since it is a function of the powder particle size [15,16]. For instance, for Al alloy powders with particles in the range of 15-50 µm, powder layer thicknesses less than 30 µm cannot be obtained.…”

Section: Introductionmentioning

confidence: 99%

Role of powder particle size on laser powder bed fusion processability of AlSi10mg alloy

Balbaa

Ghasemi

Fereiduni

et al. 2021

Additive Manufacturing

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Laser powder bed fusion (L-PBF) is one of the most promising additive manufacturing (AM) methods which provides an exceptional opportunity to improve the existing designs and move toward fabricating fine features and complex geometries with higher efficiencies. Considering the layer-wise nature of this technique, the possibility of fabricating fine features is tied to the ability to deposit thin powder layers in this process. Since the powder layer thickness is directly dictated by the powder particle size, finer powders are required to further enhance the ability of the L-PBF technique in manufacturing fine features and intricate geometries. Accordingly, this study aims at investigating the processability of fine AlSi10Mg powder (D50 = 9 µm) by using the L-PBF process. The densification level, surface quality and dimensional accuracy of the final parts are investigated in a wide range of process parameters and are compared to those manufactured by the commonly used AlSi10Mg powder (referred to as coarse powder with D50 = 40 µm).The underlying reasons behind the different processability of fine and coarse powders are explored from the density, surface quality, microhardness and dimensional accuracy viewpoints through analyzing the flowability, bed packing density and optical absorption of powders. Moreover, the process-microstructuremicrohardness relationship is assessed in detail for both fine and coarse powders. This study reinforces the idea that the utilization of fine powders in the range used in this study for L-PBF processing is rather challenging.

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Section: Introductionmentioning

confidence: 99%

Role of powder particle size on laser powder bed fusion processability of AlSi10mg alloy

Balbaa

Ghasemi

Fereiduni

et al. 2021

Additive Manufacturing

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“…CuNiSi alloys expect to satisfy adequate tensile strength and electrical conductivity because of Si content. However, alloying of copper with Sn, reduces the electrical conductivity and enhance the corrosion resistance (such as CuSn4, CuSn8, or CuSn10 powders alloys) [14].…”

Section: Introductionmentioning

confidence: 99%

The Impact Resistance of Highly Densified Metal Alloys Manufactured from Gas-Atomized Pre-Alloyed Powders

2021

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With the increasing acceleration of three-dimensional (3D) printing (for example, powder bed fusion (PBF)) of metal alloys as an additive manufacturing process, a comprehensive characterization of 3D-printed materials and structures is inevitable. The purpose of this work was to test highly densified materials produced from gas-atomized pre-alloyed metallic powders, namely 316L, Ti6Al4V, AlSi10Mg, CuNi2SiCr, CoCr28Mo6, and Inconel718, under impact conditions. This was done to demonstrate the best possible performance of such materials. Optimized spark plasma sintering (SPS) parameters (pressure, temperature, heating rate, and holding time) are applied as a novel technique of powder metallurgy. The densification level, impact site (imprint) diameter and volume, and Vickers hardness were studied. The comparison of 316L stainless steel (1) sintered by the SPS process, (2) manufactured by PBF process, and (3) coated by the physical vapor deposition (PVD) process (thin layer of TiAlN) was successfully achieved.

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“…This technology has attracted much attention in the scientific community for the possibility to manufacture part geometries impossible to manufacture using conventional processing methods [3]. It is also possible to produce materials with spatially varying microstructures, or including metastable phases [4,5]. L-PBF has become an industrially relevant method for manufacturing small batches or individualized parts quickly [6].…”

Section: Introductionmentioning

confidence: 99%

“…For more than 15 years, there has been an interest in manufacturing parts from copper [ 1 ] and precious metals like gold and silver alloys [ 2 ] using L-PBF. Target applications include heat exchangers, induction [ 3 ] and electric motor [ 4 ] coils, as well as radio frequency cathodes [ 3 ]. The manufacturing of dense, defect-free parts is, however, challenging due to the high thermal conductivity (400 W/mK) and high optical reflectivity ( R ), the complement of absorptivity ( A )

, in the near infrared spectra (>99%) of copper.…”

Section: Introductionmentioning

confidence: 99%

“… Dense samples can be achieved at lower power by using copper alloys with lower thermal conductivity. Copper alloys that have been successfully processed by L-PBF include Cu-Sn systems [ 12 , 13 , 14 ], CuCr and CuCrZr alloys [ 15 ] and CuNiSi alloys [ 4 ]. However, these alloys are less useful for many applications where high thermal conductivity is required.…”

Section: Introductionmentioning

confidence: 99%

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Laser Powder Bed Fusion of Metal Coated Copper Powders

et al. 2020

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Laser powder bed fusion (L-PBF) of copper alloys with high copper content is difficult due to the high infrared reflectivity and thermal conductivity of these alloys. In this study a simple and scalable method for coating copper powder with tin and nickel is presented, and suggested as an alloying strategy for such alloys. The coated powders were processed in a commercial L-PBF-machine at various scanning speeds. The samples made from coated powders show a lower amount of porosity compared to samples made from in-situ alloyed powders of similar composition.

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Additive manufacturing of copper alloys: Influence of process parameters and alloying elements

Cited by 28 publications

References 16 publications

Role of powder particle size on laser powder bed fusion processability of AlSi10mg alloy

Role of powder particle size on laser powder bed fusion processability of AlSi10mg alloy

The Impact Resistance of Highly Densified Metal Alloys Manufactured from Gas-Atomized Pre-Alloyed Powders

Laser Powder Bed Fusion of Metal Coated Copper Powders

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