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 article provides a comprehensive review of the advancements in additive manufacturing (AM) for copper-based alloys and composites. Copper alloys, known for their excellent thermal and electrical conductivity, are widely used in various applications such as heat exchangers, induction coils, and electronic connectors. Advanced copper alloys, with improved corrosion resistance and mechanical properties, are increasingly used in harsh industrial environments like oil and gas, marine, power plants, and water treatment. However, the complex geometries and intricate designs of these alloys pose significant challenges for traditional manufacturing methods. Additive manufacturing (AM) has revolutionized the production of complex structures by reducing processing steps, assemblies, and tooling, while eliminating the need for joining processes. However, the high thermal conductivity and reflectivity of copper present challenges in AM, particularly with fusion-based techniques like Yb-fiber laser-based processes. To overcome these challenges, various solutions have been proposed, including using high-power, low-wavelength laser sources, preheating the build chamber, employing low thermal conductivity building platforms, and adding alloying elements or composite particles to the feedstock. The article systematically reviews different AM techniques for common industrial copper alloys, including copper-chrome, copper-nickel, tin-bronze, nickel-aluminum bronze, and copper-carbon composites. It focuses on the state-of-the-art AM techniques, technological and metallurgical challenges, optimized processing variables, post-printing heat treatments, and the resulting microstructural features, physical properties, mechanical performance, and corrosion response of the AM-fabricated parts. The review also includes a comparison of the results with conventionally fabricated counterparts where applicable. The review covers the microstructure, electrical conductivity, hardness, strength, ductility, and corrosion behavior of AM-fabricated Cu-Cr alloys, as well as the effects of different post-printing heat treatments. It highlights the importance of optimizing process parameters and post-treatments to achieve the desired properties in AM-fabricated copper alloys. The article concludes with a discussion on the potential of AM in producing multi-material components with controlled microstructural features, chemical compositions, and mechanical properties, as well as the fabrication of functionally graded materials (FGMs) for various engineering applications.This article provides a comprehensive review of the advancements in additive manufacturing (AM) for copper-based alloys and composites. Copper alloys, known for their excellent thermal and electrical conductivity, are widely used in various applications such as heat exchangers, induction coils, and electronic connectors. Advanced copper alloys, with improved corrosion resistance and mechanical properties, are increasingly used in harsh industrial environments like oil and gas, marine, power plants, and water treatment. However, the complex geometries and intricate designs of these alloys pose significant challenges for traditional manufacturing methods. Additive manufacturing (AM) has revolutionized the production of complex structures by reducing processing steps, assemblies, and tooling, while eliminating the need for joining processes. However, the high thermal conductivity and reflectivity of copper present challenges in AM, particularly with fusion-based techniques like Yb-fiber laser-based processes. To overcome these challenges, various solutions have been proposed, including using high-power, low-wavelength laser sources, preheating the build chamber, employing low thermal conductivity building platforms, and adding alloying elements or composite particles to the feedstock. The article systematically reviews different AM techniques for common industrial copper alloys, including copper-chrome, copper-nickel, tin-bronze, nickel-aluminum bronze, and copper-carbon composites. It focuses on the state-of-the-art AM techniques, technological and metallurgical challenges, optimized processing variables, post-printing heat treatments, and the resulting microstructural features, physical properties, mechanical performance, and corrosion response of the AM-fabricated parts. The review also includes a comparison of the results with conventionally fabricated counterparts where applicable. The review covers the microstructure, electrical conductivity, hardness, strength, ductility, and corrosion behavior of AM-fabricated Cu-Cr alloys, as well as the effects of different post-printing heat treatments. It highlights the importance of optimizing process parameters and post-treatments to achieve the desired properties in AM-fabricated copper alloys. The article concludes with a discussion on the potential of AM in producing multi-material components with controlled microstructural features, chemical compositions, and mechanical properties, as well as the fabrication of functionally graded materials (FGMs) for various engineering applications.
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