Copper-Aluminum AM Powder Composition for Strength-Conductivity Balance
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Solution Overview
Problem
Existing copper alloy powders for additive manufacturing fail to achieve a balance between mechanical strength and electrical conductivity, limiting their application in complex-shaped products like heat sinks and heat exchangers.
Innovation Solution
A copper alloy powder with a specific composition and particle characteristics, containing 1.3 wt% to 12.5 wt% aluminum, is used for additive manufacturing, along with a gas atomization method and classification to 10 μm to 45 μm particle size, resulting in a high-quality additively manufactured product with improved mechanical strength and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If aluminum content is increased to improve mechanical strength, then Vickers hardness and engineering stress improve, but electrical conductivity deteriorates
Solution Approach 1:
The patent optimizes the aluminum content parameter within a specific range (1.3-12.5 wt%) to achieve the desired balance between mechanical strength and electrical conductivity. By precisely controlling this compositional parameter, the invention resolves the trade-off between hardness and conductivity.
2Strength
If aluminum content is increased to improve mechanical strength, then engineering stress improves, but electrical conductivity deteriorates
Solution Approach 1:
The patent optimizes the aluminum content parameter within a specific range (1.3-12.5 wt%) to achieve the desired balance between mechanical strength and electrical conductivity. By precisely controlling this compositional parameter, the invention resolves the trade-off between engineering stress and conductivity.
3Strength
If copper alloy powder with specific composition is used to achieve high mechanical strength, then Vickers hardness and engineering stress improve, but manufacturing complexity increases
Solution Approach 1:
The patent specifies a particular aluminum content range (1.3-12.5 wt%) that enables achievement of high mechanical properties through standard additive manufacturing processes, avoiding the need for complex post-processing or specialized manufacturing equipment.
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 solution enables the production of copper alloy products with a relative density of 99.0% or more, Vickers hardness of 150 Hv or more, engineering stress of 500 MPa or more, and wear amount of 0.01 g or less, suitable for complex-shaped applications.
Implementation Method 1
generating a copper alloy powder formed by adding not less than 1.3 wt % to not more than 12.5 wt % of an aluminum element to copper by a gas atomization method
Data Source
AI summary
According to this invention, it is possible to obtain a high-quality copper alloy additively manufactured product. This present invention provides a copper alloy powder for additive manufacturing used to create an additively manufactured product by an additive manufacturing method, in which the copper alloy powder for additive manufacturing contains not less than 1.3 wt % to not more than 12.5 wt % of an aluminum element, and a balance is formed by copper and unavoidable impurities. A manufacturing method of a copper alloy powder for additive manufacturing includes generating a copper alloy powder formed by adding not less than 1.3 wt % to not more than 12.5 wt % of an aluminum element to copper by a gas atomization method, and classifying the generated copper alloy powder into a particle size of not less than 10 μm to not more than 45 μm. A manufacturing method of a copper alloy additively manufactured product includes manufacturing a copper alloy additively manufactured product by an additive manufacturing apparatus using a copper alloy powder for additive manufacturing, and holding the manufactured copper alloy additively manufactured product at not less than 400° C. to not more than 600° C. for 1 hr.