Additive manufacturing of copper – H13 tool steel bi-metallic structures via Ni-based multi-interlayer

Zhang, Xinchang; Sun, Cheng; Pan, Tan; Flood, Aaron; Zhang, Yunlu; Li, Lan; Liou, Frank W.

doi:10.1016/j.addma.2020.101474

Cited by 32 publications

(25 citation statements)

References 44 publications

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“…Additive manufacturing processes offer a high degree of geometrical freedom for the fabrication of complex parts and are therefore a promising technology for pure copper applications. So far, pure copper has been processed via electron beam melting (EBM) [1][2][3][4], binder jetting (BJ) [5], laser powder bed fusion (LPBF) [6][7][8][9][10][11][12][13][14] and laser metal deposition (LMD) [15][16][17]. The highest relative densities of 99.95% and electrical conductivities of 96.24% IACS up until 2020 were achieved with the EBM process [2][3][4].…”

Section: Introductionmentioning

confidence: 99%

Physical and Geometrical Properties of Additively Manufactured Pure Copper Samples Using a Green Laser Source

et al. 2021

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So far, copper has been difficult to process via laser powder bed fusion due to low absorption with the frequently used laser systems in the infrared wavelength range. However, green laser systems have emerged recently and offer new opportunities in processing highly reflective materials like pure copper through higher absorptivity. In this study, pure copper powders from two suppliers were tested using the same machine parameter sets to investigate the influence of the powder properties on the material properties such as density, microstructure, and electrical conductivity. Samples of different wall thicknesses were investigated with the eddy-current method to analyze the influence of the sample thickness and surface quality on the measured electrical conductivity. The mechanical properties in three building directions were investigated and the geometrical accuracy of selected geometrical features was analyzed using a benchmark geometry. It could be shown that the generated parts have a relative density of above 99.95% and an electrical conductivity as high as 100% International Annealed Copper Standard (IACS) for both powders could be achieved. Furthermore, the negative influence of a rough surface on the measured eddy-current method was confirmed.

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Section: Introductionmentioning

confidence: 99%

Physical and Geometrical Properties of Additively Manufactured Pure Copper Samples Using a Green Laser Source

et al. 2021

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“…A carrier gas transports the powder through the outermost annular channel to the melting zone, while a shielding gas is used to avoid excessive oxygen pickup by the melt pool. The use of copper powders with size ranging from 30 to 110 μm have been reported in the literature [35][36][37][38]. The setup of the LMD process is schematically illustrated in Figure 5.…”

Section: Laser Metal Depositionmentioning

confidence: 99%

Additive Manufacturing of Pure Copper: Technologies and Applications

Romano¹,

Vedani²

2023

Copper - From the Mineral to the Final Application

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The opportunity to process pure copper through additive manufacturing has been widely explored in recent years, both in academic research and for industrial uses. Compared to well-established fabrication routes, the inherent absence of severe design constraints in additive manufacturing enables the creation of sophisticated copper components for applications where excellent electrical and thermal conductivity is paramount. These include electric motor components, heat management systems, heat-treating inductors, and electromagnetic devices. This chapter discusses the main additive manufacturing technologies used to fabricate pure copper products and their achievable properties, drawing attention to the advantages and the challenges they have to face considering the peculiar physical properties of copper. An insight on the topic of recycling of copper powders used in additive manufacturing is also provided. Finally, an overview of the potential areas of application of additively manufactured pure copper components is presented, highlighting the current technological gaps that could be filled by the implementation of additive manufacturing solutions.

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“…a single laser pass). Studies with great insight on laser processing parameters for AM of pure copper and copper alloys, which provide minimum energy density requirements and typical nominal parameters, can be found in several studies (Colopi et al, 2019;El-Wardany et al, 2018;Pogson et al, 2003;Popovich et al, 2016;Robinson et al, 2021;Zhang et al, 2020). However, it is important to be aware of the differences in setup (e.g.…”

Section: Sample Design and Fabricationmentioning

confidence: 99%

Laser powder bed fusion additive manufacturing of copper wicking structures: fabrication and capillary characterization

Mezghani

Nassar

Dickman

et al. 2021

RPJ

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Purpose An integral component in heat pipes (HPs) and vapor chambers (VCs) is a porous wicking structure. Traditional methods for manufacturing wicking structures within HPs and VCs involve secondary manufacturing processes and are generally limited to simple geometries. This work aims to leverage the unprecedented level of design freedom of laser powder bed fusion (LPBF) additive manufacturing (AM) to produce integrated wicking structures for HPs and VCs. Design/methodology/approach Copper wicking structures are fabricated through LPBF via partial sintering and via the formation of square, hexagonal and rectangular arrangements of micro-pins and micro-grooves, produced in multiple build directions. Wicks are characterized by conducting capillary performance analysis through the measurement of porosity, permeability and capillary rate-of-rise. Findings Copper wicking structures were successfully fabricated with capillary performance, K/reff, ranging from 0.186–1.74 µm. The rectangular-arrangement micro-pin wick presented the highest performance. Originality/value This work represents the first published report on LPBF AM of copper wicking structures for HPs/VCs applications and represents foundational knowledge for fabricating complete assemblies of copper VCs and HPs through LPBF AM.

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Additive manufacturing of copper – H13 tool steel bi-metallic structures via Ni-based multi-interlayer

Cited by 32 publications

References 44 publications

Physical and Geometrical Properties of Additively Manufactured Pure Copper Samples Using a Green Laser Source

Physical and Geometrical Properties of Additively Manufactured Pure Copper Samples Using a Green Laser Source

Additive Manufacturing of Pure Copper: Technologies and Applications

Laser powder bed fusion additive manufacturing of copper wicking structures: fabrication and capillary characterization

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