| About this Abstract |
| Meeting |
2025 TMS Annual Meeting & Exhibition
|
| Symposium
|
Printed Electronics and Additive Manufacturing: Advanced Functional Materials, Processing Concepts, and Emerging Applications
|
| Presentation Title |
Towards fast, efficient, and sustainable metal AM: Novel ultra-high speed regime in LPBF printing of pure copper |
| Author(s) |
Natalya Kublik, Laura Duenas Gonzalez, David Deisenroth, Bruno Azeredo |
| On-Site Speaker (Planned) |
Natalya Kublik |
| Abstract Scope |
Copper’s advantageous use in microelectronics and aerospace industries via additive manufacturing (AM) is hindered due to its high reflectance (>95% at 1070nm), producing excessive reflected losses in Laser Powder Bed Fusion printing, demanding high powered lasers (350-1,000W) and low speeds (<1,000mm/s) to compensate for it, and jeopardizing energy efficiency and sustainability goals for the AM industry. In this work, a new mode of laser-matter interaction is found in the lack-of-fusion porosity regime for pure copper printing, taking place at high speeds (>4,500mm/s) at low to intermediate powers (169-400W). This mode presents enhanced absorption and increased part density as the laser interacts with the melt-pool cusp and promotes multiple reflections within the pre-sintered powder bed ahead of the melt-pool rather than with the reflective melt-pool. Though relatively porous (i.e., 75-78% relative density), parts in this regime were printed 1250% faster at only 5.3% of the volumetric energy density used in literature. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Additive Manufacturing, Copper / Nickel / Cobalt, Powder Materials |