Performance improvement of laser additive manufactured Cu‒Cr alloy via continuous extrusion

Yu, Rongzhou; Zhu, Zeyu; Li, Bing; Lu, Yunzhuo; Fu, Bowen; Guan, Renguo; Lü, Xing

doi:10.1016/j.jallcom.2021.160475

Cited by 14 publications

(11 citation statements)

References 22 publications

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“…The extrusion process, however, was found to effectively reduce both the size of the chromium phase to less than 4 µm and the level of porosities. Moreover, the extrusioninduced deformation caused the crushing and alignment of fibrous Cr phases along the extrusion direction [80]. The EBSD analysis (Figure 23c,d) revealed that the extruded sample exhibits a finer grain structure with a higher density of grain boundaries, particularly in the vicinity of the Cr-rich precipitates [80].…”

Section: Microstructure Of L-ded-fabricated Cu-cr Alloysmentioning

confidence: 99%

“…Rongzhou et al [80] applied the L-DED process, followed by hot extrusion, for the manufacturing of CuCr30 alloy using a mixture of copper powder and chromium powder, with 99.95% purity and a particle size of 40-50 µm. Figure 23a and b depict the microstructure of the as-built and extruded CuCr30 samples.…”

Section: Microstructure Of L-ded-fabricated Cu-cr Alloysmentioning

confidence: 99%

“…Moreover, the extrusion-induced deformation caused the crushing and alignment of fibrous Cr phases along the extrusion direction [80]. The EBSD analysis (Figure 23c,d) revealed that the extruded sample exhibits a finer grain structure with a higher density of grain boundaries, particularly in the vicinity of the Cr-rich precipitates [80]. The TEM analysis of the extruded samples also indicated the formation of twins in the copper matrix, which contributes to the material's improved mechanical strength (Figure 23e,f) [80].…”

Section: Microstructure Of L-ded-fabricated Cu-cr Alloysmentioning

confidence: 99%

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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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Section: Microstructure Of L-ded-fabricated Cu-cr Alloysmentioning

confidence: 99%

Section: Microstructure Of L-ded-fabricated Cu-cr Alloysmentioning

confidence: 99%

Section: Microstructure Of L-ded-fabricated Cu-cr Alloysmentioning

confidence: 99%

See 1 more Smart Citation

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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show abstract

“…e CuCr alloys prepared by the vacuum consumable arc melting method have low gas content and high purity, but the equipment investment is large, and the production cost is high. To achieve a breakthrough in the preparation of high-performance CuCr alloys, domestic and foreign scholars have developed preparation methods, such as mechanical alloying methods [18][19][20][21][22][23][24][25], vacuum induction melting [26][27][28][29][30], selective laser melting [31,32], and aluminothermic reduction [33][34][35][36][37][38][39][40][41][42][43], and other preparation methods [44][45][46] at the laboratory stage [44][45][46].…”

Section: Introductionmentioning

confidence: 99%

Progress in the Preparation of Large-Size High-Performance CuCr Alloys

Han

Zhang

et al. 2022

Advances in Materials Science and Engineering

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CuCr contact material, whose mass fraction of Cr is generally in the range of 25% to 50%, is one of the most desirable contact materials for medium- and high-voltage vacuum switches. The homogeneity and denseness of CuCr alloy are the keys to its application. The infiltration and powder sintering have defects, such as uneven distribution of Cr phase, and great difficulties in preparing high-performance CuCr alloys with low gas content; the equipment investment in the vacuum consumable arc melting method is large and the production cost is high, while mechanical alloying, vacuum induction melting, and laser-selective melting as new technologies are still in the laboratory stage. From the perspective of surface modification treatment and multicomponent alloying, refinement of Cr phase grains can improve the properties of CuCr alloy. The new process of aluminothermic reduction-electromagnetic coupling refining-water and gas composite rapid cooling takes oxides as raw material and obtains a fully miscible CuCr alloy melt by aluminothermic reduction theoretically at 2848K, followed by secondary refining under electromagnetic field coupling and water-gas composite cooling and casting, which can obtain alloy ingots of 50 mm in diameter and 10 mm in height. The density and hardness of CuCr alloy prepared by this process as vacuum contact material are better than the requirements of GB/T 26867-2011, so this process has the potential to become a new-generation preparation method for large-size homogeneous high-performance CuCr alloy.

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“…Many efforts have been made by introducing a secondary phase into Cu matrix for achieving the excellent electrical and thermal conductivity as well as high strength and plasticity. Thereinto, some transitional metal micro-particles (Nb [ 4 , 5 ], Ag [ 6 , 7 ], Fe [ 8 , 9 , 10 ] and Cr [ 11 ]) are attempted and added into Cu to adjust the microcomposites, and further adjust the structural characteristic of materials by means of various alloying and preparation methods. In these Cu-based microcomposites, the specific advantage of Cu–Fe system is the relatively low cost of Fe compared with both of Cu–Nb and Cu–Ag systems [ 9 , 10 ].…”

Section: Introductionmentioning

confidence: 99%

Microstructure, Mechanical and Electrical Properties of Hybrid Copper Matrix Composites with Fe Microspheres and rGO Nanosheets

Zhang

Zhan

et al. 2022

Molecules

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Copper matrix composites have a wide application as magnetic conductive materials, electromagnetic materials, electrical discharge machining materials, etc. Such materials are expected to have a good combination of excellent electrical conductivity and good mechanical strength. In this work, micro/nano hybrid reinforcements with Fe microspheres and reduced graphene oxide (rGO) nanosheets were developed for copper matrix composites. The rGO/Fe/Cu powders were firstly wet-mixed and then densified by the vacuum hot-pressing sintering to obtain the bulk compacts. Microstructure, electrical conductivity and mechanical properties of such compacts were investigated. Microstructural result of as-sintered compacts shows that the Fe microspheres could distribute in the matrix uniformly, and rGO nanosheets exhibit both agglomerated and dispersed states. The grain size of Cu matrix decreased with the increase of the rGO content. Hardness, compression and tensile 0.2% yield strength of the as-sintered compacts were improved evidently by the addition of the hybrid Fe/rGO, comparing with pure Cu and single Fe-added composites. However, a lower electrical conductivity appeared in the more rGO-added composites, but still reached more than 33.0% international annealing copper standard (IACS). These performance change could be sought in the spatially geometrical distribution and characteristics of such micro/nano Fe/rGO hybrid addition, and the relevant mechanisms were discussed.

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Performance improvement of laser additive manufactured Cu‒Cr alloy via continuous extrusion

Cited by 14 publications

References 22 publications

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

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

Progress in the Preparation of Large-Size High-Performance CuCr Alloys

Microstructure, Mechanical and Electrical Properties of Hybrid Copper Matrix Composites with Fe Microspheres and rGO Nanosheets

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