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

2 March 2024 | Alireza Vahedi Nemani, Mahya Ghaffari, Kazem Sabet Bokati, Nima Valizade, Elham Afshari and Ali Nasiri
This review provides a comprehensive overview of advancements in additive manufacturing (AM) for copper-based alloys and composites. Copper-based materials are widely used due to their excellent thermal and electrical conductivity, and their applications range from heat exchangers to electronic connectors. However, their use in harsh environments requires improved mechanical properties, such as corrosion resistance and strength. Additive manufacturing has revolutionized the production of complex structures by reducing processing steps and eliminating the need for joining processes. However, the high thermal conductivity and reflectivity of copper pose challenges in AM processes, particularly with Yb-fiber lasers. To overcome these challenges, various solutions have been proposed, including the use of high-power lasers, preheating, and the addition of alloying elements or composite particles to the feedstock material. The review systematically examines different aspects of AM processing for 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, technological and metallurgical challenges, optimized processing variables, the impact of post-printing heat treatments, resulting microstructural features, physical properties, mechanical performance, and corrosion response of AM-fabricated parts. A comprehensive comparison of results with conventionally fabricated counterparts is provided where applicable. The review also discusses the challenges associated with AM of copper alloys, including the formation of defects such as discontinuities, pores, and cracks, and the anisotropic properties of AM-processed products. Solutions to improve the AM processability of copper alloys include the use of high-power lasers, preheating, employing laser sources with lower wavelengths, using building platforms with lower thermal conductivity, and adding alloying elements to the feedstock material. The review highlights the importance of optimizing process parameters and post-printing heat treatments to achieve desired microstructural features and mechanical properties in AM-fabricated copper alloys. The review concludes with a discussion on the potential of AM for the fabrication of copper-based composites and the need for further research to fully understand and optimize the AM process for these materials.This review provides a comprehensive overview of advancements in additive manufacturing (AM) for copper-based alloys and composites. Copper-based materials are widely used due to their excellent thermal and electrical conductivity, and their applications range from heat exchangers to electronic connectors. However, their use in harsh environments requires improved mechanical properties, such as corrosion resistance and strength. Additive manufacturing has revolutionized the production of complex structures by reducing processing steps and eliminating the need for joining processes. However, the high thermal conductivity and reflectivity of copper pose challenges in AM processes, particularly with Yb-fiber lasers. To overcome these challenges, various solutions have been proposed, including the use of high-power lasers, preheating, and the addition of alloying elements or composite particles to the feedstock material. The review systematically examines different aspects of AM processing for 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, technological and metallurgical challenges, optimized processing variables, the impact of post-printing heat treatments, resulting microstructural features, physical properties, mechanical performance, and corrosion response of AM-fabricated parts. A comprehensive comparison of results with conventionally fabricated counterparts is provided where applicable. The review also discusses the challenges associated with AM of copper alloys, including the formation of defects such as discontinuities, pores, and cracks, and the anisotropic properties of AM-processed products. Solutions to improve the AM processability of copper alloys include the use of high-power lasers, preheating, employing laser sources with lower wavelengths, using building platforms with lower thermal conductivity, and adding alloying elements to the feedstock material. The review highlights the importance of optimizing process parameters and post-printing heat treatments to achieve desired microstructural features and mechanical properties in AM-fabricated copper alloys. The review concludes with a discussion on the potential of AM for the fabrication of copper-based composites and the need for further research to fully understand and optimize the AM process for these materials.
Reach us at info@study.space
Understanding Advancements in Additive Manufacturing for Copper-Based Alloys and Composites%3A A Comprehensive Review