Journal
ADDITIVE MANUFACTURING
Volume 35, Issue -, Pages -Publisher
ELSEVIER
DOI: 10.1016/j.addma.2020.101418
Keywords
Powder surface modification; Modified CuCr1 powder; Laser powder bed fusion; Selective laser melting; Copper reflectivity
Funding
- Flanders Innovation & Entrepreneurship Agency (Agentschap Innoveren en Ondernemen (VLAIO)) [150010]
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Owing to the high optical reflectivity of copper, silver, and gold in the infrared region, high laser power is required for laser-based additive manufacturing (L-AM). This increases the risk of damaging the laser optics due to sustained backreflections and renders L-AM of reflective metals an unsustainable technology. To tackle this issue, a novel, industrially upscalable powder surface modification method is proposed and validated using a CuCr1 alloy. The surface of CuCr1 powder is modified by the outward diffusion of chromium in a nitrogen atmosphere, forming a rim around the powder particles. This doubled the optical absorption of the powder. Consequently, a mere 20% of the laser energy is required to process the surface-modified powder by laser powder bed fusion compared to the virgin CuCr1 powder. The fabricated parts demonstrate a very high thermal conductivity of 370 +/- 15 W/(mK) and tensile strength of 439 +/- 19 MPa, after applying a suitable post-heat treatment.
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