Abstract:The poor wettability and weak interfacial bonding of diamond/copper composites are due to the incompatibility between diamond and copper which are inorganic nonmetallic and metallic material, respectively, which limit their further application in next-generation heat management materials. Coating copper and titanium on the diamond particle surface could effectively modify and improve the wettability of the diamond/copper interface via electroless plating and evaporation methods, respectively. Here, these dense… Show more
“…Considering that 1200 W is enough to get a continuous fusion when carbon is present, the reduction in the power laser reaches 40% to fuse copper in this experimental series. When it comes to the literature comparison, this reduction can be much more expressive since densities such as 100 kW/mm 2 are rarely obtained for Cu or Cu alloys [ 18 , 35 ].…”
Section: Resultsmentioning
confidence: 99%
“…The main drawback when adding carbon to copper is its segregation generating pores and cracks in the final metal part [ 15 , 16 , 17 ]. Preliminary studies have shown reduced copper reflectance when using polymeric materials as an absorbing layer [ 13 , 18 ]. In addition, using a multilayer stack of several graded metal-carbon layers followed by an amorphous carbon film produces excellent selective solar absorbers [ 19 ].…”
Thin and ultrathin carbon films reduce the laser energy required for copper powder fusion in selective laser melting (SLM). The low absorption of infrared (IR) radiation and its excellent thermal conductivity leads to an intricate combination of processing parameters to obtain high-quality printed parts in SLM. Two carbon-based sacrificial thin films were deposited onto copper to facilitate light absorption into the copper substrates. Graphite-like (3.5 µm) and ultra-thin (25 nm) amorphous carbon films were deposited by aerosol spraying and direct current magnetron sputtering, respectively. The melting was analyzed for several IR (1.06 µm) laser powers in order to observe the coating influence on the energy absorption. Scanning electron microscopy showed the topography and cross-section of the thermally affected area, electron backscatter diffraction provided the surface chemical composition of the films, and glow-discharge optical emission spectroscopy (GDOES) allowed the tracking of the in-deep chemical composition of the 3D printed parts using carbon film-covered copper. Ultra-thin films of a few tens of nanometers could reduce fusion energy by about 40%, enhanced by interferences phenomena. Despite the lower energy required, the melting maintained good quality and high wettability when using top carbon coatings. A copper part was SLM printed and associated with 25 nm of carbon deposition between two copper layers. The chemical composition analysis demonstrated that the carbon was intrinsically removed during the fusion process, preserving the high purity of the copper part.
“…Considering that 1200 W is enough to get a continuous fusion when carbon is present, the reduction in the power laser reaches 40% to fuse copper in this experimental series. When it comes to the literature comparison, this reduction can be much more expressive since densities such as 100 kW/mm 2 are rarely obtained for Cu or Cu alloys [ 18 , 35 ].…”
Section: Resultsmentioning
confidence: 99%
“…The main drawback when adding carbon to copper is its segregation generating pores and cracks in the final metal part [ 15 , 16 , 17 ]. Preliminary studies have shown reduced copper reflectance when using polymeric materials as an absorbing layer [ 13 , 18 ]. In addition, using a multilayer stack of several graded metal-carbon layers followed by an amorphous carbon film produces excellent selective solar absorbers [ 19 ].…”
Thin and ultrathin carbon films reduce the laser energy required for copper powder fusion in selective laser melting (SLM). The low absorption of infrared (IR) radiation and its excellent thermal conductivity leads to an intricate combination of processing parameters to obtain high-quality printed parts in SLM. Two carbon-based sacrificial thin films were deposited onto copper to facilitate light absorption into the copper substrates. Graphite-like (3.5 µm) and ultra-thin (25 nm) amorphous carbon films were deposited by aerosol spraying and direct current magnetron sputtering, respectively. The melting was analyzed for several IR (1.06 µm) laser powers in order to observe the coating influence on the energy absorption. Scanning electron microscopy showed the topography and cross-section of the thermally affected area, electron backscatter diffraction provided the surface chemical composition of the films, and glow-discharge optical emission spectroscopy (GDOES) allowed the tracking of the in-deep chemical composition of the 3D printed parts using carbon film-covered copper. Ultra-thin films of a few tens of nanometers could reduce fusion energy by about 40%, enhanced by interferences phenomena. Despite the lower energy required, the melting maintained good quality and high wettability when using top carbon coatings. A copper part was SLM printed and associated with 25 nm of carbon deposition between two copper layers. The chemical composition analysis demonstrated that the carbon was intrinsically removed during the fusion process, preserving the high purity of the copper part.
“…This Special Issue article covers a wide range of forming materials, including steel [1,9] and other iron-based alloys [11], magnesium alloys [3], titanium alloys [6,12], copper alloys [7], aluminum alloys [13], composites (e.g., CF/PA12 [4], copper/titanium-coated diamond [14]) and, in particular, metallic multi-materials (e.g., NiTi/CuSn10 [2], copper/steel [7]) and 4D-printing materials (e.g., NiTi shape memory alloys [2,15], smart materials for soft interactive hydrogel [5]). et al [12] investigated types of Ti-6Al-4V (TC4) materials with different porosities fabricated via L-PBF using different printing parameters.…”
Section: Materials Of Laser Additive Manufacturing In This Special Issuementioning
confidence: 99%
“…Zhang et al [14] used the L-PBF technique to fabricate titanium-and copper-coated diamond/copper composites. The microstructure, roughness, interface bonding, thermal and mechanical performance were studied.…”
Section: Materials Of Laser Additive Manufacturing In This Special Issuementioning
Laser-based additive manufacturing (LAM) is a revolutionary advanced digital manufacturing technology developed in recent decades, which is also a key strategic technology for technological innovation and industrial sustainability [...]
“…AM technology emerged in the 1990s and has been under development for approximately three decades [8]. Unlike "subtractive manufacturing" (e.g., cutting, drilling, and milling) and "equal-material manufacturing" (e.g., welding, casting, and forging), AM is built on 3D models [9], relies on layer by layer printing-extrusion, sintering [10,11], melting, light curing, and jetting to form solids from metallic or non-metallic materials [12,13].…”
Spatter is an inherent, unpreventable, and undesired phenomenon in laser powder bed fusion (L-PBF) additive manufacturing. Spatter behavior has an intrinsic correlation with the forming quality in L-PBF because it leads to metallurgical defects and the degradation of mechanical properties. This impact becomes more severe in the fabrication of large-sized parts during the multi-laser L-PBF process. Therefore, investigations of spatter generation and countermeasures have become more urgent. Although much research has provided insights into the melt pool, microstructure, and mechanical property, reviews of spatter in L-PBF are still limited. This work reviews the literature on the in situ detection, generation, effects, and countermeasures of spatter in L-PBF. It is expected to pave the way towards a novel generation of highly efficient and intelligent L-PBF systems.
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