Copper Composite Powder Coating for Laser-Absorbing 3D Printing
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Solution Overview
Problem
Copper and copper alloy powders have low laser absorption coefficients, leading to inefficient melting or sintering during additive manufacturing, resulting in articles with lower density and electrical conductivity.
Innovation Solution
A metal powder for additive manufacturing is produced by mixing copper-containing particles with laser-absorbing powders such as TiB2 or Y2O3, which adhere to the surfaces of the copper-containing particles, enhancing laser absorption and facilitating efficient melting or sintering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper or copper alloy powder is used for additive manufacturing, then the article can be manufactured with good electrical conductivity, but the laser absorption coefficient is low causing insufficient melting or sintering
Solution Approach 1:
The patent applies composite materials by combining copper-containing particles with laser-absorbing powder to create a composite powder structure. The laser-absorbing powder (such as carbon black, iron oxide, or copper oxide) is mixed with copper powder to form particles where the copper provides electrical conductivity while the laser-absorbing component increases laser absorption coefficient, thereby resolving the contradiction between maintaining electrical conductivity and improving energy absorption.
Solution Approach 2:
The patent applies local quality by having different parts of the powder particle serve different functions: the copper-containing core provides electrical conductivity, while the laser-absorbing powder coating or embedded within the particle provides enhanced laser absorption. This local differentiation of material properties allows simultaneous optimization of both electrical conductivity and energy absorption characteristics.
2Reliability
If higher laser output is used to melt or sinter copper powder, then the melting or sintering can be achieved, but the process becomes less efficient and requires longer irradiation time
Solution Approach 1:
The patent applies parameter changes by modifying the optical parameters of the copper powder through the addition of laser-absorbing materials. This changes the laser absorption coefficient from a low value (typical of pure copper) to a high value, enabling efficient melting or sintering at standard laser outputs and reducing the required irradiation time, thereby improving manufacturing efficiency.
3Ease of manufacture
If copper powder with low laser absorption coefficient is used, then the material can be processed, but the resulting article has lower density due to insufficient melting or sintering
Solution Approach 1:
The patent uses composite materials where the laser-absorbing powder (such as carbon black, iron oxide, or copper oxide) is distributed within or on the surface of copper particles. This composite structure enables the material to absorb laser energy efficiently during processing while maintaining good flowability and processability, resulting in high-density articles with proper melting and sintering.
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 resulting metal powder achieves high laser absorption, enabling the production of articles with improved density and electrical conductivity.
Implementation Method 1
a copper powder, wherein an absorption coefficient is 18.9% to 65.0% for light with a wavelength of λ = 1060 nm
Implementation Method 2
irradiating a thinly spread metal powder with a laser beam or electron beam, based on a cross-sectional data of an article to be manufactured, and melting and solidifying or sintering a part of the metal powder
Implementation Method 3
laser-absorbing powder adhering to surfaces of the copper-containing particles
Implementation Method 4
melting and solidifying or sintering a part of the metal powder to form a layer
Implementation Method 5
melting and solidifying or sintering a part of the metal powder to form a layer
Data Source
Figure 1
AI summary
A metal powder for additive manufacturing, the metal powder containing copper-containing particles 1 and laser-absorbing powder 2 adhering to surfaces of the copper-containing particles 1.