Coated Copper Powder for Laser Additive Manufacturing
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Solution Overview
Problem
In metal additive manufacturing using the laser method, there is a need for a metal powder that can be efficiently melted while maintaining high conductivity, as the characteristics required differ from those for electron beam methods, and existing solutions do not effectively address the unique challenges of the laser method.
Innovation Solution
A copper or copper alloy powder is coated with a metal material that has high laser absorption and does not easily dissolve in copper, such as elements like Gd, Ho, Lu, Mo, Nb, Os, Re, Ru, Tb, Tc, Th, U, V, W, Y, Zr, Cr, Rh, Hf, La, Ce, Pr, Nd, Sm, and Ti, which enhances laser absorption and maintains high conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If copper or copper alloy powder is used for laser additive manufacturing, then high conductivity is maintained, but laser absorption efficiency is insufficient
Solution Approach 1:
The patent applies composite materials by coating copper or copper alloy powder with a metal material that has high laser beam absorption. This creates a composite structure where the copper core maintains high conductivity while the coating layer enhances laser absorption efficiency, resolving the contradiction between these two properties.
Solution Approach 2:
The patent applies local quality by coating only the surface of the copper powder particles with a metal material having high laser absorption. The core copper material retains its high conductivity properties while the surface coating locally enhances laser absorption, allowing different regions of the same particle to have different functional properties.
2Productivity
If surface treatment is performed to improve laser absorption, then melting efficiency increases, but dissolution of coating in copper may occur
Solution Approach 1:
The patent selects a metal material for the coating that forms a stable, non-dissolving layer on the copper powder surface. This coating acts as a stable, durable surface treatment that maintains its integrity during the laser additive manufacturing process, preventing dissolution and ensuring consistent performance throughout the manufacturing cycle.
3Productivity
If metal powder is used without coating, then conductivity is maintained, but work efficiency in laser processing is reduced
Solution Approach 1:
The patent uses composite materials by combining copper powder with a metal coating layer that has high laser beam absorption. This composite structure enables efficient energy absorption from the laser while maintaining the high conductivity of the copper core, thereby improving work efficiency without sacrificing energy absorption capability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The coated powder is efficiently melted with a laser, maintaining high conductivity and allowing for improved work efficiency, with the coating's higher melting point and lower thermal conductivity ensuring property retention and efficient heat use, even when reused.
Implementation Method 1
by coating a surface of a copper or copper alloy powder with a metal material having high absorption of a laser beam
Implementation Method 2
melting the metal powder layer by scanning the metal powder layer with an electron beam or a laser beam
Implementation Method 3
because the composition of the coating formed on the surface of the copper or copper alloy has a lower thermal conductivity than copper, heat of the laser beam can be used more efficiently
Implementation Method 4
melting the metal powder layer by scanning the metal powder layer with an electron beam or a laser beam and subsequently solidifying the metal powder layer
Implementation Method 5
melting the metal powder layer by scanning the metal powder layer with an electron beam or a laser beam and subsequently solidifying the metal powder layer
Data Source
AI summary
A metal powder in which a coating made of one or more types of elements selected from Gd, Ho, Lu, Mo, Nb, Os, Re, Ru, Tb, Tc, Th, Tm, U, V, W, Y, Zr, Cr, Rh, Hf, La, Ce, Pr, Nd, Pm, and Sm is formed on a surface of a copper or copper alloy powder, wherein a thickness of the coating is 5 nm or more and 500 nm or less. An object of the present invention to provide a metal powder for metal additive manufacturing based on the laser method which can be efficiently melted with a laser while maintaining the high conductivity of copper or copper alloy, and a molded object produced by using such metal powder.