LASER – Powder Bed Fusion technology is an Additive Manufacturing (AM) process consisting of the production of components with complex geometries, especially for the biomedical, automotive, and aerospace fields. In L-PBF, a LASER beam selectively melts regions of a powder bed, previously spread over already processed powder layers, forming an iterative process. Copper presents greater difficulties in being additively manufactured with L-PBF than other alloys such as stainless steel and Inconel, due to its high reflectivity at wavelengths of the common fiber lasers. AM Pure Copper has only recently achieved the capabilities to reach values adequate for industrial electrical applications for properties such as relative density, mechanical resistance, and electrical conductivity. This is possible thanks to the implementation of strategies such as high-power laser systems. This thesis work is an experimental study on the electrical conductivity of AM Pure copper, produced with L-PBF with high power laser (nominal 1kW). In the first phase, AM Pure Copper characterized and its validity as a material for electrical applications in the E-Mobility sector is verified under mechanical and electrical aspects. In the second experimental phase, influences of process parameters are studied, focusing on Volumetric Energy Density (VED), and subsequently optimal sets of parameters both in terms of electrical conductivity and productivity are searched. This master thesis project was part of EIT-Manufacturing MSc Double Degree “Additive Manufacturing For Full Flexibility”, completed at Politecnico di Milano and Technische Universität Wien. Addtoshape Srl offered the opportunity develop a thesis project in a work environment in the manufacturing sector, regarding pure copper L PBF.
La tecnologia LASER – Powder Bed Fusion (L-PBF) è un processo di manifattura additiva (AM) che consiste nella produzione di componenti dalle geometrie complesse, specialmente per l’ambito biomedicale, automotive ed aerospaziale. Nel L PBF, un fascio LASER fonde selettivamente regioni di un letto di polvere, precedentemente steso sopra del materiale già fuso, dando vita ad un processo iterativo. Il rame presenta maggiori difficoltà rispetto ad altre leghe quali acciaio inossidabile ed Inconel ad essere stampato in 3D con metodo L-PBF, per via della sua alta riflettività nelle lunghezze d’onda dei comuni laser a fibra ottica. Il rame puro prodotto per manifattura additiva solo recentemente ha ottenuto la possibilità di raggiungere caratteristiche di densità relativa, resistenza meccanica e conducibilità elettrica adeguate ad applicazioni industriali. Questo è reso possibile tramite l’implementazione di strategie quali ad esempio sistemi laser ad alta potenza. Questo lavoro di tesi è uno studio sperimentale della conducibilità elettrica del rame puro prodotto per Laser – Powder Bed Fusion con laser ad alta potenza (1kW nominale). In una prima fase, il rame puro prodotto per AM viene caratterizzato e viene verificata la sua validità come materiale per applicazioni nel campo E-Mobility, sotto aspetti meccanici ed elettrici. Nella seconda fase sperimentale, vengono studiate le influenze dei parametri di processo, focalizzandosi sulla Densità di Energia Volumetrica VED, e vengono ricercati set di parametri ottimali in termini di conducibilità elettrica e produttività. Questa tesi magistrale è parte del percorso di Doppia Laurea MSc “Additive Manufacturing For Full Flexibility” offerto da EIT-Manufacturing, e completato presso Politecnico di Milano e L’Università Tecnica di Vienna. Addtoshape Srl ha offerto l’opportunità di sviluppare un progetto di tesi all’interno di un ambiente lavorativo del settore manifatturiero, dedicato alla L-PBF del rame.
Characterization of the electrical properties of copper parts produced by laser powder bed fusion
Sacco Balderico, Filippo
2022/2023
Abstract
LASER – Powder Bed Fusion technology is an Additive Manufacturing (AM) process consisting of the production of components with complex geometries, especially for the biomedical, automotive, and aerospace fields. In L-PBF, a LASER beam selectively melts regions of a powder bed, previously spread over already processed powder layers, forming an iterative process. Copper presents greater difficulties in being additively manufactured with L-PBF than other alloys such as stainless steel and Inconel, due to its high reflectivity at wavelengths of the common fiber lasers. AM Pure Copper has only recently achieved the capabilities to reach values adequate for industrial electrical applications for properties such as relative density, mechanical resistance, and electrical conductivity. This is possible thanks to the implementation of strategies such as high-power laser systems. This thesis work is an experimental study on the electrical conductivity of AM Pure copper, produced with L-PBF with high power laser (nominal 1kW). In the first phase, AM Pure Copper characterized and its validity as a material for electrical applications in the E-Mobility sector is verified under mechanical and electrical aspects. In the second experimental phase, influences of process parameters are studied, focusing on Volumetric Energy Density (VED), and subsequently optimal sets of parameters both in terms of electrical conductivity and productivity are searched. This master thesis project was part of EIT-Manufacturing MSc Double Degree “Additive Manufacturing For Full Flexibility”, completed at Politecnico di Milano and Technische Universität Wien. Addtoshape Srl offered the opportunity develop a thesis project in a work environment in the manufacturing sector, regarding pure copper L PBF.| File | Dimensione | Formato | |
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https://hdl.handle.net/10589/219402