Nanoparticle-enhanced absorptivity of copper during laser powder bed fusion

Tertuliano, Ottman A.; DePond, Philip J.; Doan, David; Matthews, Manyalibo J.; Gu, X. Wendy; Cai, Wei; Lew, Adrian J.

doi:10.1016/j.addma.2021.102562

Title: Nanoparticle-enhanced absorptivity of copper during laser powder bed fusion

Journal Article · Thu Dec 22 00:00:00 EST 2022 · Additive Manufacturing

DOI:https://doi.org/10.1016/j.addma.2021.102562· OSTI ID:1876693

Tertuliano, Ottman A. ^[1]; DePond, Philip J. ^[2]; Doan, David ^[1]; Matthews, Manyalibo J. ^[3]; Gu, X. Wendy ^[1]; Cai, Wei ^[1]; Lew, Adrian J. ^[1]

Stanford University, CA (United States)
Stanford University, CA (United States); Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)
Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)

We report laser powder bed fusion (LPBF) of pure copper for thermal and electrical applications is hampered by its low near-infrared absorptivity and high thermal diffusivity. These material properties make it very difficult to localize the thermal energy needed to produce high density 3D printed parts. Modification of metal powders via nanoparticle additives is a promising approach to increasing absorptivity, but the effect of nanoparticles on absorptivity and melting behavior during LPBF is not well understood. In this study, we developed an in situ calorimetry system to measure effective absorptivity during LPBF on copper substrates. We decorated copper substrates using three nanoparticle systems (CuS, TiB₂, multilayer graphene flakes) and demonstrated an enhanced absorptivity of the decorated substrates relative to pure copper. Graphene nanoflakes resulted in the highest improved absorption relative to pure copper from 0.09 to 0.48, due to their stability at high laser scanning powers. A thermomechanical model with convective heat transfer provided confidence in the measurements by reproducing the experimental melt pool traces. Full 3D cylindrical prints demonstrated an improvement in relative density of the copper-graphene powder prints (in the range of 0.930–0.992), relative to that of as-purchased copper powder prints (in the range of 0.854–0.972). This work provides a fundamental study of nanoparticle-enabled LPBF of highly reflective metals and demonstrates a viable route for expanding the library of reliably printable metals.

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Research Organization:: Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)

Sponsoring Organization:: USDOE National Nuclear Security Administration (NNSA)

Grant/Contract Number:: AC52-07NA27344; ECCS-1542152

OSTI ID:: 1876693

Report Number(s):: LLNL-JRNL-836846; 1054124

Journal Information:: Additive Manufacturing, Vol. 51, Issue N/A; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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