Laser powder bed fusion (L-PBF) of Cu and CuCrZr parts: Influence of an absorptive physical vapor deposition (PVD) coating on the printing process
Additive Manufacturing, 2021
Abstract Laser powder bed fusion (L-PBF) of copper and copper alloys remain a challenge because o... more Abstract Laser powder bed fusion (L-PBF) of copper and copper alloys remain a challenge because of its low optical absorption and high thermal conductivity. L-PBF experiments were performed to print 2D (patches) and 3D (cubes) objects with pure copper under a low laser power (270 W max.). Patches reveal different surface morphologies allowing to select the best printing conditions for cubes. The highest reached cube relative density is 87.9%. To increase this value, a 1064 nm-absorptive physical vapor deposition (PVD) CrZr coating was performed on the copper powder to enhance its optical absorption. X-ray Photoelectron Spectrometry (XPS) and Auger measurements reveal the coating is oxidized, but increases the resulting CuCrZr powder optical absorption from 39% (value for pure Cu) to 81.8%. The CuCrZr powder was then used in the L-PBF process, and patches and cubes were successfully printed. The highest CuCrZr cube relative density reached 94.3%, highlighting the positive influence of a powder coating to create hard-to-melt metals or hard-to-atomized alloys under low laser power.
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Papers by Eric De Vito