Effect of Particle Size Distribution on Laser Powder Bed Fusion Manufacturability of Copper

• Published in: BHM. Berg- und hüttenmännische Monatshefte Vol. 166; no. 5; pp. 256 - 262
• Main Authors: Bonesso, Massimiliano, Rebesan, Pietro, Gennari, Claudio, Mancin, Simone, Dima, Razvan, Pepato, Adriano, Calliari, Irene
• Format: Journal Article
• Language: English
• Published: Vienna Springer Vienna 2021; Springer Nature B.V
• Subjects: Copper; Densification; Earth and Environmental Science; Earth Sciences; Heat exchangers; Lasers; Manufacturability; Mechanical properties; Mineral Resources; Originalarbeit; Particle size; Particle size distribution; Physical properties; Powder beds; Process parameters; Surface roughness; Thermal conductivity; Thermodynamic properties; Particle Size Distribution; Porosität; Additive Manufacturing; Laser Powder Bed Fusion; Porosity; Copper; Laser Pulverbettfusion; Kupfer; Partikelgrößenverteilung; Additive Fertigung
• ISSN: 0005-8912; 1613-7531
• DOI: 10.1007/s00501-021-01107-0

One of the major benefits of the Laser Powder Bed Fusion (LPBF) technology is the possibility of fabrication of complex geometries and features in only one-step of production. In the case of heat exchangers in particular, this is very convenient for the fabrication of conformal cooling channels which can improve the performance of the heat transfer capability. Yet, obtaining dense copper parts printed via LPBF presents two major problems: the high reflectivity of 1 μm (the wavelength of commonly used laser sources) and the high thermal conductivity of copper that limits the maximum local temperature that can be attained. This leads to the formation of porous parts.
In this contribution, the influence of the particle size distribution of the powder on the physical and mechanical properties of parts produced via LPBF is studied. Three copper powders lots with different particle size distributions are used in this study. The effect on densification from two laser scan parameters (scan speed and hatching distance) and the influence of contours scans on the lateral surface roughness is reported. Subsequently, samples manufactured with the optimal process parameters are tested for thermal and mechanical properties evaluation.