Electron beam powder bed fusion of copper components: a review of mechanical properties and research opportunities

Sharabian, Elmira; Leary, Martin; Fraser, Darren; Gulizia, Stefan

doi:10.1007/s00170-022-09922-6

Cited by 14 publications

(7 citation statements)

References 44 publications

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“…Additionally, a 4-dimensional process map of the Ti-6Al-4 V alloy was constructed using the selecting boundary conditions approach. Notably, the dynamic programming approach consumed a substantial amount of time (972-3793 s) to determine the next set of 16 conditions, whereas the selecting boundary condition approach proved significantly faster (3)(4)(5)(6)(7)(8)(9)(10)(11) in determining the next trial of 16 conditions. A process map can be constructed using machine learning through model selection and hyperparameter tuning using SMGO-TPE.…”

Section: Discussionmentioning

confidence: 99%

“…Powder bed fusion using an electron beam (PBF-EB) is an additive manufacturing (AM) technology facilitating the near-net shaping of complex-shaped metal parts for various industrial applications, such as aerospace, biomedical, and automotive fields [1][2][3]. PEB-EB has found utility across a range of alloy systems, such as Ti alloy [4], Ni alloy [5,6], Co alloy [7][8][9], pure-Cu [10,11], and others [12]. Achieving defect-free parts with PBF-EB typically involves constructing a process map that defines an optimized process window [6,13].…”

Section: Introductionmentioning

confidence: 99%

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Developing auto process mapping technique for powder bed fusion using an electron beam

Aoyagi,

Ono,

Yanagihara

et al. 2023

Prog Addit Manuf

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Powder bed fusion using an electron beam offers promise for manufacturing intricate metal parts. However, process optimization for defect-free parts proves costly and time-consuming. Many studies have investigated process optimization and defect prediction methods, but automating process optimization remains a significant challenge. This study developed and validated software to automatically determine i + 1-th trial conditions based on the results of the i-th trial experiment. Two algorithms were implemented and evaluated:—a dynamic programming approach and a selecting boundary conditions approach. The latter method considerably reduced the time required to determine the next conditions compared to the former approach. Considering a process mapping experiment requiring real-time trial condition determination during the build, we chose the selecting boundary conditions approach. The selecting boundary conditions approach was used to conduct a process mapping experiment to validate the software for constructing a process map using machine learning. The model and hyperparameters were optimized using sequential model-based global optimization with a tree-structured Parzen estimator. The process map underwent four updates using the developed software to determine i + 1-th trial conditions and construct a process map from the results of the i-th trial experiment.

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Section: Discussionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Developing auto process mapping technique for powder bed fusion using an electron beam

Aoyagi,

Ono,

Yanagihara

et al. 2023

Prog Addit Manuf

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“…Since the production of complex configurations of heat exchangers for metal hydride reactors is limited by traditional manufacturing methods, the use of additive manufacturing is proposed to reduce economic costs and facilitate the implementation of complex designs. Powder bed fusion, directed energy deposition, material jetting and sheet lamination can be used in order to produce the metal parts of heat exchangers [ 187 , 188 , 189 , 190 , 191 , 192 , 193 , 194 , 195 , 196 , 197 , 198 , 199 , 200 , 201 , 202 , 203 , 204 , 205 , 206 , 207 , 208 , 209 ] ( Figure 34 ).…”

Section: Additive Manufacturing For Heat Exchangersmentioning

confidence: 99%

State of the Art in Development of Heat Exchanger Geometry Optimization and Different Storage Bed Designs of a Metal Hydride Reactor

et al. 2023

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The efficient operation of a metal hydride reactor depends on the hydrogen sorption and desorption reaction rate. In this regard, special attention is paid to heat management solutions when designing metal hydride hydrogen storage systems. One of the effective solutions for improving the heat and mass transfer effect in metal hydride beds is the use of heat exchangers. The design of modern cylindrical-shaped reactors makes it possible to optimize the number of heat exchange elements, design of fins and cooling tubes, filter arrangement and geometrical distribution of metal hydride bed elements. Thus, the development of a metal hydride reactor design with optimal weight and size characteristics, taking into account the efficiency of heat transfer and metal hydride bed design, is the relevant task. This paper discusses the influence of different configurations of heat exchangers and metal hydride bed for modern solid-state hydrogen storage systems. The main advantages and disadvantages of various configurations are considered in terms of heat transfer as well as weight and size characteristics. A comparative analysis of the heat exchangers, fins and other solutions efficiency has been performed, which makes it possible to summarize and facilitate the choice of the reactor configuration in the future.

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“…In addition, using a multilayer stack of several graded metal-carbon layers followed by an amorphous carbon film produces excellent selective solar absorbers [ 19 ]. Nevertheless, pure copper’s physical properties are significantly affected by impurities [ 20 ]. Thus, with the recent development of printable graphene conductor inks, the joint of a graphite-like layer in minimal quantities that does not alter Cu properties appears to be an easy alternative to manage Cu’s fusion using IR energy [ 15 , 21 ].…”

Section: Introductionmentioning

confidence: 99%

The Use of Sacrificial Graphite-like Coating to Improve Fusion Efficiency of Copper in Selective Laser Melting

Crespi

Nordet²,

Peyre³

et al. 2023

Materials

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Thin and ultrathin carbon films reduce the laser energy required for copper powder fusion in selective laser melting (SLM). The low absorption of infrared (IR) radiation and its excellent thermal conductivity leads to an intricate combination of processing parameters to obtain high-quality printed parts in SLM. Two carbon-based sacrificial thin films were deposited onto copper to facilitate light absorption into the copper substrates. Graphite-like (3.5 µm) and ultra-thin (25 nm) amorphous carbon films were deposited by aerosol spraying and direct current magnetron sputtering, respectively. The melting was analyzed for several IR (1.06 µm) laser powers in order to observe the coating influence on the energy absorption. Scanning electron microscopy showed the topography and cross-section of the thermally affected area, electron backscatter diffraction provided the surface chemical composition of the films, and glow-discharge optical emission spectroscopy (GDOES) allowed the tracking of the in-deep chemical composition of the 3D printed parts using carbon film-covered copper. Ultra-thin films of a few tens of nanometers could reduce fusion energy by about 40%, enhanced by interferences phenomena. Despite the lower energy required, the melting maintained good quality and high wettability when using top carbon coatings. A copper part was SLM printed and associated with 25 nm of carbon deposition between two copper layers. The chemical composition analysis demonstrated that the carbon was intrinsically removed during the fusion process, preserving the high purity of the copper part.

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Electron beam powder bed fusion of copper components: a review of mechanical properties and research opportunities

Cited by 14 publications

References 44 publications

Developing auto process mapping technique for powder bed fusion using an electron beam

Developing auto process mapping technique for powder bed fusion using an electron beam

State of the Art in Development of Heat Exchanger Geometry Optimization and Different Storage Bed Designs of a Metal Hydride Reactor

The Use of Sacrificial Graphite-like Coating to Improve Fusion Efficiency of Copper in Selective Laser Melting

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