Copper Powder Composition for High-Conductivity Laser Lamination
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Solution Overview
Problem
Existing techniques for laminating and shaping copper powder do not consider electrical conductivity, making it difficult to produce a laminated and shaped copper object with high electrical conductivity using conventional methods.
Innovation Solution
A laminating and shaping copper powder is created by mixing pure copper powder with nano-oxide in specific weight percentages and particle diameters, allowing for the formation of a laminated and shaped object with an electrical conductivity of 80% IACS or more.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional laminating and shaping techniques are used on copper powder, then the process can be performed with existing equipment, but the electrical conductivity of the resulting object cannot reach 80% IACS or more
Solution Approach 1:
The invention changes the chemical composition parameters by introducing nano-oxide at precisely controlled concentrations (0.01-0.20 wt%). This parameter change modifies the physical properties of copper powder, enabling stable laser processing while achieving 80% IACS or higher electrical conductivity in the final product.
Solution Approach 2:
The invention creates a composite material system by combining copper powder with nano-oxide. This composite approach allows the material to exhibit both the high electrical conductivity of pure copper and the processability benefits of oxide-containing composites, resolving the contradiction between conductivity and manufacturability.
2Temperature
If the energy density is increased to overcome thermal energy diffusion, then melting can be achieved, but the electrical conductivity decreases below 80% IACS
Solution Approach 1:
By changing the compositional parameters (adding nano-oxide at 0.01-0.20 wt%), the invention enables effective laser energy absorption at moderate energy densities (500-1500 J/mm³) without requiring excessive heating that would damage electrical conductivity properties.
3Productivity
If the laser power is increased to improve shaping efficiency, then productivity increases, but the energy density exceeds the optimal range of 500-1500 J/mm³
Solution Approach 1:
The invention optimizes the compositional parameters (nano-oxide content and particle size distribution) to enable efficient laser processing within the 500-1500 J/mm³ energy density range, achieving both high productivity and precise manufacturing control simultaneously.
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 method enables the production of a laminated and shaped copper object with high electrical conductivity and density using existing apparatuses with an energy density of about 1,000 J/mm3, overcoming the challenges of thermal energy diffusion and reflection.
Implementation Method 1
shaping a laminated and shaped object of at least one layer by irradiating the laminating and shaping copper powder spread in the at least one layer with a laser beam
Implementation Method 2
irradiating the laminating and shaping copper powder spread in the at least one layer with a laser beam while scanning the laser beam
Data Source
AI summary
The present invention provides a laminating and shaping copper powder capable of shaping a laminated and shaped object of copper having a high electrical conductivity of, for example, 80% IACS or more. The present invention is a laminating and shaping copper powder obtained by mixing a nano-oxide of equal to or more than 0.01 wt % and equal to or less than 0.20 wt % and a pure copper powder. There is also provided a laminated and shaped object using the laminating and shaping copper powder of the present invention. There are also provided a manufacturing method of the laminated and shaped object using the laminating and shaping copper powder of the present invention and a laminating and shaping apparatus using the laminating and shaping copper powder.