Stable formation of powder bed laser fused 99.9% silver

Robinson, John; Stanford, Mark; Arjunan, Arun

doi:10.1016/j.mtcomm.2020.101195

Cited by 27 publications

(35 citation statements)

References 39 publications

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“…In the SLM process, the additive results are affected by parameters, such as laser power, defocusing amount (spot size), scanning trajectory, scanning speed, layer spacing, etc. [63][64][65]. A schematic diagram of SLM technology is shown in Figure 1 [59].…”

Section: Selective Laser Meltingmentioning

confidence: 99%

A Review on Additive Manufacturing of Pure Copper

et al. 2021

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With the development of the aerospace and automotive industries, high heat exchange efficiency is a challenge facing the development of various industries. Pure copper has excellent mechanical and physical properties, especially high thermal conductivity and electrical conductivity. These excellent properties make pure copper the material of choice for the manufacture of heat exchangers and other electrical components. However, the traditional processing method is difficult to achieve the production of pure copper complex parts, so the production of pure copper parts through additive manufacturing has become a problem that must be overcome in industrial development. In this article, we not only reviewed the current status of research on the structural design and preparation of complex pure copper parts by researchers using selective laser melting (SLM), selective electron beam melting (SEBM) and binder jetting (BJ) in recent years, but also reviewed the forming, physical properties and mechanical aspects of pure copper parts prepared by different additive manufacturing methods. Finally, the development trend of additive manufacturing of pure copper parts is also prospected.

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Section: Selective Laser Meltingmentioning

confidence: 99%

A Review on Additive Manufacturing of Pure Copper

et al. 2021

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“…1 at wt.% ratio of Cu-76%, W-17%, and Ag-7%. Cu and Ag are difficult to laser process due to their highly reflective and thermally conductive properties [40,42,57,58]. The high melt point of W also adds to the challenges for SLM [59,60].…”

Section: Additive Manufacturing Copper-tungsten-silver (Cu-w-ag)mentioning

confidence: 99%

“…The atomised powders morphology is displayed in Figure 1 at wt.% ratio of Cu-76%, W-17% and Ag-7%. Cu and Ag are difficult to laser process due to their highly reflective and thermally conductive properties (Robinson et al, 2020a;Robinson et al, 2021;Colopi et al, 2018;Guschlbauer et al, 2018). The high melt point of W also adds to the challenges for SLM (Xiong et al, 2020;Zhou et al, 2015).…”

Section: Additive Manufacturing Copper-tungsten-silvermentioning

confidence: 99%

“…However, for SLM in general, increasing scan speed reduces laser energy input leading to a smaller weld pool and track width. Similarly, when the scan speed is lowered, the increased exposure time leads to a higher temperature at the melt pool consuming increased powder volume resulting in a wider melt pool (Robinson et al, 2020a). Therefore, understanding the SLM parameter effects for optimum anti-SARS-CoV-2 filter fabrication is required.…”

Section: Development Of the Surrogate Model 231 Selective Laser Melting Parameter Influence For Pore Formationmentioning

confidence: 99%

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Additive manufacturing of anti-SARS-CoV-2 Copper-Tungsten-Silver alloy

Robinson

Arjunan

Baroutaji

et al. 2021

RPJ

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Purpose The COVID-19 pandemic emphasises the need for antiviral materials that can reduce airborne and surface-based virus transmission. This study aims to propose the use of additive manufacturing (AM) and surrogate modelling for the rapid development and deployment of novel copper-tungsten-silver (Cu-W-Ag) microporous architecture that shows strong antiviral behaviour against severe acute respiratory syndrome coronavirus 2 (SARS-CoV-2). Design/methodology/approach The research combines selective laser melting (SLM), in-situ alloying and surrogate modelling to conceive the antiviral Cu-W-Ag architecture. The approach is shown to be suitable for redistributed manufacturing by representing the pore morphology through a surrogate model that parametrically manipulates the SLM process parameters: hatch distance (h_d), scan speed (S_s) and laser power (L_p). The method drastically simplifies the three-dimensional (3D) printing of microporous materials by requiring only global geometrical dimensions solving current bottlenecks associated with high computed aided design data transfer required for the AM of porous materials. Findings The surrogate model developed in this study achieved an optimum parametric combination that resulted in microporous Cu-W-Ag with average pore sizes of 80 µm. Subsequent antiviral evaluation of the optimum architecture showed 100% viral inactivation within 5 h against a biosafe enveloped ribonucleic acid viral model of SARS-CoV-2. Research limitations/implications The Cu-W-Ag architecture is suitable for redistributed manufacturing and can help reduce surface contamination of SARS-CoV-2. Nevertheless, further optimisation may improve the virus inactivation time. Practical implications The study was extended to demonstrate an open-source 3D printed Cu-W-Ag antiviral mask filter prototype. Social implications The evolving nature of the COVID-19 pandemic brings new and unpredictable challenges where redistributed manufacturing of 3D printed antiviral materials can achieve rapid solutions. Originality/value The papers present for the first time a methodology to digitally conceive and print-on-demand a novel Cu-W-Ag alloy that shows high antiviral behaviour against SARS-CoV-2.

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“…In addition to their pure form, Ag and Cu are also being investigated as alloying elements to exploit their desired properties 37,38 compounding the interest in their potential laser processing. So far L-PBF processing of high purity Ag, Cu and CuAg alloys has seen limited research with varying success 31,39,40 .…”

Section: Introductionmentioning

confidence: 99%

Mechanical and thermal performance of additively manufactured copper, silver and copper–silver alloys

Robinson

Arjunan

Baroutaji

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part L:

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On-demand additive manufacturing (three-dimensional printing) offers great potential for the development of functional materials for the next generation of energy-efficient devices. In particular, novel materials suitable for efficient dissipation of localised heat fluxes and non-uniform thermal loads with superior mechanical performance are critical for the accelerated development of future automotive, aerospace and renewable energy technologies. In this regard, this study reports the laser powder bed fusion processing of high purity (>99%) copper (Cu), silver (Ag) and novel copper–silver (CuAg) alloys ready for on-demand additive manufacturing. The processed materials were experimentally analysed for their relative density, mechanical and thermal performance using X-ray computed tomography, destructive tensile testing and laser flash apparatus, respectively. It was found that while Ag featured higher failure strains, Cu in comparison showed a 109%, 17% and 59% improvement in yield strength ([Formula: see text]), Young’s modulus ( E) and ultimate tensile strength, respectively. As such the [Formula: see text], E and ultimate tensile strength for laser powder bed fusion Cu is comparable to commercially available laser powder bed fusion Cu materials. CuAg alloys, however, significantly outperformed Ag, Cu and all commercial Cu materials when it came to mechanical performance offering significantly superior performance. The [Formula: see text], E and ultimate tensile strength for the novel CuAg composition were 105%, 33% and 94% higher in comparison to Cu. Although slightly different, the trend continued with a 106% and 91% rise for [Formula: see text] and ultimate tensile strength, respectively, for CuAg in comparison to industry-standard Cu. Unfortunately, E values for industry-standard Cu alloys were not available. When it came to thermal performance, laser powder bed fusion Ag was found to offer a 70% higher thermal diffusivity in comparison to Cu despite the variation in density and porosity. CuAg alloys however only showed a 0.8% variation in thermal performance despite a 10–30% increase in Ag. Overall, the study presents a new understanding regarding the three-dimensional printing and performance of Cu, Ag and CuAg alloys.

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Stable formation of powder bed laser fused 99.9% silver

Cited by 27 publications

References 39 publications

A Review on Additive Manufacturing of Pure Copper

A Review on Additive Manufacturing of Pure Copper

Additive manufacturing of anti-SARS-CoV-2 Copper-Tungsten-Silver alloy

Mechanical and thermal performance of additively manufactured copper, silver and copper–silver alloys

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