Experimental and numerical characterization of pure copper heat sinks produced by laser powder bed fusion

Sciacca, Gabriele; Sinico, Mirko; Cogo, Giacomo; Bigolaro, Davide; Pepato, A.; Esposito, J.

doi:10.1016/j.matdes.2022.110415

Cited by 19 publications

(6 citation statements)

References 67 publications

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“…The L-PBF technique was first developed in 1995 at the Fraunhofer Institute ILT in Germany, with the powder bed fusion process employed [42]. As illustrated in figure 3(a), the L-PBF process begins with precise lowering of the build platform, followed by the deposition of a thin, uniform powder layer.…”

Section: L-pbfmentioning

confidence: 99%

Advances and challenges in direct additive manufacturing of dense ceramic oxides

Fan,

Tan,

Kang

et al. 2024

Int. J. Extrem. Manuf.

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Ceramic oxides, renowned for their exceptional combination of mechanical, thermal, and chemical properties, are indispensable in numerous crucial applications across diverse engineering fields. However, conventional manufacturing methods frequently grapple with limitations, such as challenges in shaping intricate geometries, extended processing durations, elevated porosity, and substantial shrinkage deformations. Direct additive manufacturing (dAM) technology stands out as a state-of-the-art solution for ceramic oxides production. It facilitates the one-step fabrication of high-performance, intricately designed components characterized by dense structures. Importantly, dAM eliminates the necessity for post-heat treatments, streamlining the manufacturing process and enhancing overall efficiency. This study undertakes a comprehensive review of recent developments in dAM for ceramic oxides, with a specific emphasis on the laser powder bed fusion and laser directed energy deposition techniques. A thorough investigation is conducted into the shaping quality, microstructure, and properties of diverse ceramic oxides produced through dAM. Critical examination is given to key aspects including feedstock preparation, laser–material coupling, formation and control of defects, in-situ monitoring and simulation. This paper concludes by outlining future trends and potential breakthrough directions, taking into account current gaps in this rapidly evolving field.

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Section: L-pbfmentioning

confidence: 99%

Advances and challenges in direct additive manufacturing of dense ceramic oxides

Fan,

Tan,

Kang

et al. 2024

Int. J. Extrem. Manuf.

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“…[29][30][31] Interestingly, the LPBF fabrication of AlSi10Mg and Cu parts with lattice structures for heat sink applications has already been reported. [32,33] The literature on LPBF of pure refractory materials and their alloys, especially Mo and TZM, is very limited. As for that of LPBF-processed Mo and TZM parts with thin features or lattice structures for heat sink applications, literature is lacking.…”

Section: Doi: 101002/adem202301409mentioning

confidence: 99%

“…[ 29‐31 ] Interestingly, the LPBF fabrication of AlSi10Mg and Cu parts with lattice structures for heat sink applications has already been reported. [ 32,33 ]…”

Section: Introductionmentioning

confidence: 99%

Laser Powder Bed Fusion Additive Manufacturing of Mo and TZM Exoskeleton with Cu Infiltration for New Heat Sinks Configuration

Ramakrishnan,

Kumar,

Hudon

et al. 2023

Adv Eng Mater

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This study reports the fabrication and characterization of molybdenum (Mo) metal and titanium‐zirconium‐molybdenum (TZM) alloy exoskeletons with honeycomb cavity structures (HCS) that are infiltrated with oxygen‐free high conductivity (OFHC) Cu under an inert atmosphere as a potential replacement for Cu‐Mo‐Cu laminate in heat sink applications for power electronics semiconductors like GaAs. The thermal expansion behavior and the thermal loading of the starting Mo and TZM structures, and of the Cu‐infiltrated parts are evaluated. The fabricated Mo and TZM structures with density >99% and Mo‐based heat sinks with improved CTE (6.6 × 10−6 K−1) when compared to conventional Cu‐Mo‐Cu laminated heat sinks (CTE = 7.6 × 10−6 K−1). The new Mo and TZM structures promise superior performance due to their closer CTE to that of GaAs and similar semiconductors (CTE = 5.7 × 10−6 K−1). Exposure to temperatures up to 1073 K did not affect the Mo microstructure due to the inherent resistance to recrystallization, while exposure to 1373 K did reduce hardness. In contrast, TZM exoskeletons showed resistance to recrystallization even at 1373 K. The fabricated composite heat sinks showed thermal diffusivity (≈61 × 106 m2 s−1) that is within the upper limits of those reported for commercial laminated heat sinks (45 to 65 × 106 m2 s−1).

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“…In recent decades, laser cladding has been widely used to fabricate coatings due to its advantages of high efficiency and low cost [8][9][10][11][12]. As a coating material, a single metal powder or alloy powder plays an indispensable role in laser cladding technology [13,14].…”

Section: Introductionmentioning

confidence: 99%

Effect of a Substrate’s Preheating Temperature on the Microstructure and Properties of Ni-Based Alloy Coatings

Liu,

Jin,

et al. 2024

Lubricants

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Laser cladding is a new technology to fabricate a coating on the surface of a metal substrate. The properties on copper substrates are usually not very good due to the high thermal conductivity and reflectivity. The appropriate preheating temperature is helpful to fabricate coatings with good quality and properties, especially for copper substrates. In order to investigate the effect of different preheating temperatures, four coatings with different preheating temperatures (100, 200, 300 and 400 °C) were fabricated via a laser on a copper substrate. The microstructures and properties of four coatings were investigated using SEM, XRD, EDS, a Vickers microhardness meter, a wear tester and an electrochemical workstation. The results show that the elements from Ni-based alloy powder were uniformly distributed among the binding region, which obtained a good metallurgical bonding. The microstructure was mainly composited of cellular, dendrite and plane crystals, and the main reinforced phases were γ (Fe, Ni), Cr0.09Fe0.7Ni0.21, WC and Ni3B. The values of average microhardness of the four coatings were 614.3, 941.6, 668.1 and 663.1 HV0.5, respectively. The wear rates of the four coatings were 9.7, 4.9, 12.5 and 13.3 × 10−5 mm3·N−1·m−1, respectively, which were less than that of the copper substrate (4.3 × 10−3 mm3·N−1·m−1). The decrease in wear rate was due to the existence of the reinforced phases, such as WC, Ni3B, M7C3 (M=Fe, Cr) and Cr0.09Fe0.7Ni0.21. The fine crystals in the coating preheated at 200 °C also improved the wear resistance. Additionally, the minimum values of corrosion current density were 3.26 × 10−5, 2.34 × 10−7, 4.02 × 10−6 and 4.21 × 10−6 mA·mm−2, respectively. It can be seen that the coating preheated at 200 °C had higher microhardness, lower wear rates and better corrosion resistance due to the existence of reinforced phases and fine and uniform crystals.

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Experimental and numerical characterization of pure copper heat sinks produced by laser powder bed fusion

Cited by 19 publications

References 67 publications

Advances and challenges in direct additive manufacturing of dense ceramic oxides

Advances and challenges in direct additive manufacturing of dense ceramic oxides

Laser Powder Bed Fusion Additive Manufacturing of Mo and TZM Exoskeleton with Cu Infiltration for New Heat Sinks Configuration

Effect of a Substrate’s Preheating Temperature on the Microstructure and Properties of Ni-Based Alloy Coatings

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