Fabricating Copper Components with Electron Beam Melting

Frigola, P.; Harrysson, Ola; Horn, Timothy; West, Harvey; Aman, Ron; Rigsbee, J. M.; Ramirez, D. A.; Murr, Lawrence E.; Medina, Francisco; Wicker, Ryan B.; Rodriguez, Emmanuel

doi:10.31399/asm.amp.2014-07.p020

Cited by 15 publications

(4 citation statements)

References 11 publications

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“…59,61,75 Process engineering A further field of applications for cellular materials is process engineering where the permeability is used. In this case, the possibility to produce functional parts where a cellular material is integrated serving as heat exchanger, 45,47 mixer or carrier for catalytic materials engineering 72,73,77,97 is utilised, see Fig. 12a and b.…”

Section: Medical Applicationsmentioning

confidence: 99%

Additive manufacturing of metallic components by selective electron beam melting — a review

Körner

2016

International Materials Reviews

786

356

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Selective electron beam melting (SEBM) belongs to the additive manufacturing technologies which are believed to revolutionise future industrial production. Starting from computer-aided designed data, components are built layer by layer within a powder bed by selectively melting the powder with a high power electron beam. In contrast to selective laser melting (SLM), which can be used for metals, polymers and ceramics, the application field of the electron beam is restricted to metallic components since electric conductivity is required. On the other hand, the electron beam works under vacuum conditions, can be moved at extremely high velocities and a high beam power is available. These features make SEBM especially interesting for the processing of high-performance alloys. The present review describes SEBM with special focus on the relationship between process characteristics, material consolidation and the resulting materials and component properties.

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Section: Medical Applicationsmentioning

confidence: 99%

Additive manufacturing of metallic components by selective electron beam melting — a review

Körner

2016

International Materials Reviews

786

356

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“…According to Table 5, it can be understood that the sample contained 100% silver-coated copper particles in its structure showed better yield strength than other samples. Frigola et al (2014) in their study, they produced copper based compact samples by using electron beam melting (EBM) manufacturing method. They stated that the yield strength of the copperbased compact sample, whose relative density was calculated as more than 99% after production by EBM method, was 76 MPa [53].…”

Section: Hardness and Tensile Strengthmentioning

confidence: 99%

“…Frigola et al (2014) in their study, they produced copper based compact samples by using electron beam melting (EBM) manufacturing method. They stated that the yield strength of the copperbased compact sample, whose relative density was calculated as more than 99% after production by EBM method, was 76 MPa [53]. In our study, the relative density of the 100% Cu compact sample (C1) was approximately 97.1%, and the yield strength was 69 MPa.…”

Section: Hardness and Tensile Strengthmentioning

confidence: 99%

Novel advanced copper-silver materials produced from recycled dendritic copper powders using electroless coating and hot pressing

et al. 2022

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In this study, copper powders with dendritic morphology were produced by the electrolysis method, and then silver coating was applied to these powders by an electroless coating method. The bulk samples were fabricated by hot pressing method using different ratios of copper and silver-plated copper powders. The results showed that the electroless silver coating layer provided a strong bond at the particle boundaries of the samples, significantly improving the physical and mechanical properties of the materials. Accordingly, the hardness, tensile strength, electrical and thermal conductivity values of the samples produced from silver-plated dendritic copper particles were determined to be approximately 98 HB, 185 MPa, 102 IACS% and 402 W mK −1 , respectively. In addition, the oxidation resistance of the sample produced from completely silver-coated copper powders is 4 times higher than that of pure copper.

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“…For example, pure copper with excellent thermal conductivity (5.8 × 10 7 S/m) is primarily desired for induction heat coils, cooling channels, heat exchangers, radiators, or radiofrequency cathodes [2,3]. Also, pure copper is commonly used in electrical applications due to its great balance of low electrical resistivity (1.72 × 10 −8 Ω) and reasonable price compared to precious metals such as gold and silver [4]. However, the inferior mechanical strength and wear resistance of pure copper in comparison with other engineering materials became an incentive for researchers to improve their mechanical properties [5] with the addition of different alloying elements.…”

Section: Introduction 1copper Alloys and Their Applicationsmentioning

confidence: 99%

Advancements in Additive Manufacturing for Copper-Based Alloys and Composites: A Comprehensive Review

Vahedi Nemani,

Ghaffari,

Sabet Bokati

et al. 2024

JMMP

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Copper-based materials have long been used for their outstanding thermal and electrical conductivities in various applications, such as heat exchangers, induction heat coils, cooling channels, radiators, and electronic connectors. The development of advanced copper alloys has broadened their utilization to include structural applications in harsh service conditions found in industries like oil and gas, marine, power plants, and water treatment, where good corrosion resistance and a combination of high strength, wear, and fatigue tolerance are critical. These advanced multi-component structures often have complex designs and intricate geometries, requiring extensive metallurgical processing routes and the joining of the individual components into a final structure. Additive manufacturing (AM) has revolutionized the way complex structures are designed and manufactured. It has reduced the processing steps, assemblies, and tooling while also eliminating the need for joining processes. However, the high thermal conductivity of copper and its high reflectivity to near-infrared radiation present challenges in the production of copper alloys using fusion-based AM processes, especially with Yb-fiber laser-based techniques. To overcome these difficulties, various solutions have been proposed, such as the use of high-power, low-wavelength laser sources, preheating the build chamber, employing low thermal conductivity building platforms, and adding alloying elements or composite particles to the feedstock material. This article systematically reviews different aspects of AM processing of common industrial copper alloys and composites, including copper-chrome, copper-nickel, tin-bronze, nickel-aluminum bronze, copper-carbon composites, copper-ceramic composites, and copper-metal composites. It focuses on the state-of-the-art AM techniques employed for processing different copper-based materials and the associated technological and metallurgical challenges, optimized processing variables, the impact of post-printing heat treatments, the resulting microstructural features, physical properties, mechanical performance, and corrosion response of the AM-fabricated parts. Where applicable, a comprehensive comparison of the results with those of their conventionally fabricated counterparts is provided.

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Fabricating Copper Components with Electron Beam Melting

Cited by 15 publications

References 11 publications

Additive manufacturing of metallic components by selective electron beam melting — a review

Additive manufacturing of metallic components by selective electron beam melting — a review

Novel advanced copper-silver materials produced from recycled dendritic copper powders using electroless coating and hot pressing

Advancements in Additive Manufacturing for Copper-Based Alloys and Composites: A Comprehensive Review

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