Laser Powder Bed Fusion of Metal Coated Copper Powders

Lindström, Viktor; Liashenko, Oleksii; Zweiacker, Kai; Derevianko, S. І.; Morozovych, V. V.; Lyashenko, Yurij; Leinenbach, Christian

doi:10.3390/ma13163493

Cited by 36 publications

(22 citation statements)

References 35 publications

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“…Therefore, the use of green or blue laser may broaden the L-PBF processing window, and copper parts exhibiting full density could be fabricated in both conduction and keyhole modes, similar to the conventional infrared fiber laser (λ = 1080 nm) based L-PBF processing windows of Ti-6Al-4V and SS 316L alloys. Besides, a broader L-PBF processing window against infrared lasers for highly conductive copper and copper alloys can be achieved by utilizing surface-modified copper powders which exhibit high optical absorption, as validated by Jadhav et al [27,[50][51][52] and Lindström et al [53]. However, the latter approach is valid when, at least, a small amount of alloying is permitted.…”

Section: = √ × × × Equation (5)mentioning

confidence: 98%

Laser-based powder bed fusion additive manufacturing of pure copper

Jadhav

Goossens

Kinds

et al. 2021

Additive Manufacturing

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In this article, the laser-based powder bed fusion (L-PBF) processing behavior of pure copper powder is evaluated by employing a conventional infrared fiber laser with a wavelength of 1080 nm, a small focal spot diameter of 37.5 µm, and power levels up to 500 W. It is shown that bulk solid copper parts with near full density (ρ Archimedes = 99.3 ± 0.2%, ρ Optical = 99.8 ± 0.1%) can be produced using a laser power of 500 W for the chosen combination of powder particle size, L-PBF settings, and pure copper baseplate. Moreover, at 500 W, parts with a relative density exceeding 99% are manufactured within a volumetric energy density window of 230 -310 J/mm 3 , while laser power levels below 500 W did not produce parts with a relative density above 99%. An analytical model is used to elucidate the L-PBF processing behavior, wherein both conduction and keyhole regimes corresponding to the employed L-PBF settings are identified. The analytical model-based results predict that the bulk solid copper parts with near full density are produced in a keyhole regime prior to the onset of keyholeinduced porosity, which is in accordance with the porosity types observed in the parts. The L-PBF fabricated copper parts exhibit an electrical conductivity of 94 ± 1% compared to the international annealed copper standard (IACS) and demonstrate a tensile strength of 211 ± 4 MPa, a yield strength of 122 ± 1 MPa, and an elongation at break of 43 ± 3% in the as-built condition.

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Section: = √ × × × Equation (5)mentioning

confidence: 98%

Laser-based powder bed fusion additive manufacturing of pure copper

Jadhav

Goossens

Kinds

et al. 2021

Additive Manufacturing

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“…Tin-nickel coating was implemented on the copper powder using the immersion deposition method. The results showed less porosity on the corresponding samples, indicating that the part density achieved from the tin-nickel coating was higher than those samples made from pre-alloyed powder [14]. In general, the coating process is complex and influenced by several parameters regarding the coating variables, such as temperature, PH, potential difference, etc., which will significantly affect the coating properties.…”

Section: Introductionmentioning

confidence: 97%

Process–Structure–Property Relationships of Copper Parts Manufactured by Laser Powder Bed Fusion

et al. 2021

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The process–structure–property relationships of copper laser powder bed fusion (L-PBF)-produced parts made of high purity copper powder (99.9 wt %) are examined in this work. A nominal laser beam diameter of 100 μm with a continuous wavelength of 1080 nm was employed. A wide range of process parameters was considered in this study, including five levels of laser power in the range of 200 to 370 W, nine levels of scanning speed from 200 to 700 mm/s, six levels of hatch spacing from 50 to 150 μm, and two layer thickness values of 30 μm and 40 μm. The influence of preheating was also investigated. A maximum relative density of 96% was obtained at a laser power of 370 W, scanning speed of 500 mm/s, and hatch spacing of 100 μm. The results illustrated the significant influence of some parameters such as laser power and hatch spacing on the part quality. In addition, surface integrity was evaluated by surface roughness measurements, where the optimum Ra was measured at 8 μm ± 0.5 μm. X-ray photoelectron spectroscopy (XPS) and energy-dispersive X-ray spectroscopy (EDX) were performed on the as-built samples to assess the impact of impurities on the L-PBF part characteristics. The highest electrical conductivity recorded for the optimum density-low contaminated coils was 81% IACS.

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“…In this frame, the use of coated powders has been significantly increasing in PM, aiming to improve the powders' processability or to modify the final part's microstructural, mechanical, physical, and thermal properties. By coating the powders' surface, it is possible to change melting temperatures [15], the flowability [15,16], and the absorbance [17][18][19][20][21] of the powder itself. Microstructural characteristics can also be modified by coating with a second phase, particularly nanoceramic particles such as ZrO 2 , Al 2 O 3 , B 4 C, SiC, TiB 2 , C-based structures [22][23][24].…”

Section: Introductionmentioning

confidence: 99%

“…For increasing laser absorptivity, at the emission wavelength of the laser commonly adopted in L-PBF (1064 or 1070 nm), an increase of powders' surface roughness can be provided [62,63]. Another solution might be coating powders with a material characterized by a lower reflectance [17][18][19]21,[63][64][65]. Poor flowability of powders can be attributed to the influence of van der Waals (vdW) forces.…”

Section: Introductionmentioning

confidence: 99%

Coated Metal Powders for Laser Powder Bed Fusion (L-PBF) Processing: A Review

Bidulský¹,

Gobber

Bidulská

et al. 2021

Metals

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In the last years, functionalized powders are becoming of increasing interest in additive manufacturing (particularly in laser powder bed fusion processing, L-PBF), due to their improved flowability and enhanced processability, particularly in terms of laser absorbance. Functionalized powders may also provide higher final mechanical or physical properties in the manufactured parts, like an increased hardness, a higher tensile strength, and density levels close to theoretical. Coatings represent a possible interesting approach for powders’ functionalizing. Different coating methods have been studied in the past years, either mechanical or non-mechanical. This work aims to present an overview of the currently obtained coated powders, analyzing in detail the processes adopted for their production, the processability of the coated systems, and the mechanical and physical properties of the final parts obtained by using L-PBF for the powders processing.

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Laser Powder Bed Fusion of Metal Coated Copper Powders

Cited by 36 publications

References 35 publications

Laser-based powder bed fusion additive manufacturing of pure copper

Laser-based powder bed fusion additive manufacturing of pure copper

Process–Structure–Property Relationships of Copper Parts Manufactured by Laser Powder Bed Fusion

Coated Metal Powders for Laser Powder Bed Fusion (L-PBF) Processing: A Review

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