Laser metal deposition of pure copper on stainless steel with blue and IR diode lasers

Asano, Kohei; Tsukamoto, Masahiro; Sechi, Yoshihisa; Sato, Yuji; Masuno, Shinichiro; Higashino, Ritsuko; Hara, Takahiro; Sengoku, Masanori; Yoshida, Minoru

doi:10.1016/j.optlastec.2018.06.012

Cited by 53 publications

(18 citation statements)

References 10 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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“…Changing the laser wavelength from the infrared region (fiber laser λ = 1070 ± 10 nm) to the visible region (green laser λ = 515 nm [14], and blue laser λ = 450 nm [15]) is inspired by the low optical reflectivity of copper for the visible radiation. Although fully dense copper parts could be manufactured using green or blue lasers via other laser-based AM processes [16][17][18], researchers have not yet disclosed the density, mechanical, electrical, or thermal properties of such LPBF fabricated parts. Moreover, the newly developed green or blue laser technology is costly and still in the research phase.…”

Section: Introductionmentioning

confidence: 99%

Highly conductive and strong CuSn0.3 alloy processed via laser powder bed fusion starting from a tin-coated copper powder

Jadhav

Deprez

et al. 2020

Additive Manufacturing

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Despite the high demand, the successful fabrication of fully dense, highly conductive, and strong copper components via laser powder bed fusion (LPBF) is not readily evident. This is mainly due to the low optical absorption of copper, which inhibits the complete melting of copper powders when using commercially available fiber-laser-based LPBF machines. Accordingly, this article proposes a novel approach of using optically absorptive metal-coated copper powders for the fabrication of fully dense, highly conductive, and strong copper components via LPBF. To validate this approach, the surface of the copper powder is modified by applying a very thin (62 ± 14 nm) layer of metallic tin via an immersion plating technique. The application of only a 0.28 wt% of metallic tin coating significantly improved the room temperature powder optical absorption by ~170% at the fiber laser wavelength. Consequently, crack-free and fully dense copper parts combining high thermal conductivity of 334 ± 4 W/(m•K) and electrical conductivity of 80 ± 1% international annealed copper standard (%IACS) with a good tensile strength of 256 ± 14 MPa, yield strength of 203 ± 4 MPa, and ductility of 21 ± 2 % have been fabricated using a fiber laser with an output laser power of 500 W.Furthermore, the article also describes the negative influence of the presence of a high amount of (0.091 wt%) sulfur, which originates from the organic additives during sub-optimal coating conditions, on the LPBF processing behavior of CuSn alloys. As such, high sulfur-containing tin-coated copper powders do not allow the fabrication of fully dense parts due to the occurrence of solidification cracks and the formation of pores. Subsequently, the optimum tin coating methodology, which limits the amount of sulfur below 0.0025 wt%, is described. The use of sulfur-free powder is recommended for the successful LPBF processing of fully dense parts made of copper and copper alloys.

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“…For instance, among engineering structural alloys, the melting point can span from 600 • C in Al to 3400 • C in W [91]. The energy absorption rate is also worth considering when a highly reflected element, such as Cu, is part of the alloy [98]. In SLM work, a refractory HEA comprises of NbMoTaW was deposited [99].…”

Section: Capturing and Meltingmentioning

confidence: 99%

A Review on Metallic Alloys Fabrication Using Elemental Powder Blends by Laser Powder Directed Energy Deposition Process

et al. 2020

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The laser powder directed energy deposition process is a metal additive manufacturing technique, which can fabricate metal parts with high geometric and material flexibility. The unique feature of in-situ powder feeding makes it possible to customize the elemental composition using elemental powder mixture during the fabrication process. Thus, it can be potentially applied to synthesize industrial alloys with low cost, modify alloys with different powder mixtures, and design novel alloys with location-dependent properties using elemental powder blends as feedstocks. This paper provides an overview of using a laser powder directed energy deposition method to fabricate various types of alloys by feeding elemental powder blends. At first, the advantage of laser powder directed energy deposition in manufacturing metal alloys is described in detail. Then, the state-of-the-art research and development in alloys fabricated by laser powder directed energy deposition through a mix of elemental powders in multiple categories is reviewed. Finally, critical technical challenges, mainly in composition control are discussed for future development.

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Laser metal deposition of pure copper on stainless steel with blue and IR diode lasers

Cited by 53 publications

References 10 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

Highly conductive and strong CuSn0.3 alloy processed via laser powder bed fusion starting from a tin-coated copper powder

A Review on Metallic Alloys Fabrication Using Elemental Powder Blends by Laser Powder Directed Energy Deposition Process

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