Tin-Modified Copper Powder for Laser Lamination Shaping
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Solution Overview
Problem
Pure copper's high electrical conductivity prevents the formation of high-density laminated and shaped products using fiber laser lamination shaping due to laser beam reflection, which hinders the absorption of thermal energy needed for melting.
Innovation Solution
Adding a tin element to pure copper powder to adjust its electrical conductivity and achieve a suitable particle size and density for effective lamination shaping, allowing for the production of high-density and conductive laminated products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pure copper is used for lamination shaping, then high electrical conductivity is achieved, but high density (98.5% or more) cannot be obtained due to laser beam reflection
Solution Approach 1:
The invention changes the material parameter by adding tin element to pure copper, transforming it from pure copper to copper-tin alloy powder. This parameter change modifies the electrical conductivity to an appropriate level that enables effective laser beam absorption, thereby achieving high-density laminated products (98.5% or more) while maintaining sufficient electrical conductivity (20% IACS or more).
Solution Approach 2:
The invention uses composite material approach by creating copper-tin alloy powder where tin particles are dispersed in the copper matrix. This composite structure optimizes both electrical conductivity and laser absorption characteristics, enabling the material to achieve high density through lamination shaping while retaining adequate electrical conductivity for practical applications.
2Reliability
If pure copper powder is used, then high electrical conductivity is maintained, but thermal energy absorption is insufficient due to laser beam reflection
Solution Approach 1:
The invention modifies the electrical conductivity parameter of copper by adding tin element, which simultaneously changes the thermal properties and laser absorption characteristics. The optimized electrical conductivity range (20% IACS or more) corresponds to improved thermal energy absorption capability, allowing the material to effectively absorb laser beam energy for melting and densification during lamination shaping.
3Manufacturing precision
If copper alloy powder is used to improve density, then manufacturing precision improves, but electrical conductivity decreases
Solution Approach 1:
The invention optimizes the alloying parameter by adding a specific amount of tin element (0.01-10 mass%) to copper, creating copper-tin alloy powder with balanced properties. This precise parameter control achieves high density (98.5% or more) in laminated products while maintaining electrical conductivity at 20% IACS or more, resolving the trade-off between density and conductivity.
Solution Approach 2:
The invention applies local quality principle by controlling the distribution and concentration of tin elements within the copper matrix. The tin particles are dispersed locally in the copper powder, creating regions with optimized properties that collectively achieve both high density and adequate electrical conductivity in the final laminated product.
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 modified copper powder enables the creation of laminated and shaped products with densities of 98.5% or more and electrical conductivities of 20% IACS or more, overcoming the limitations of pure copper in lamination shaping.
Implementation Method 1
laser-beam lamination shaping uses a fiber laser as a heat source, and forms an arbitrary shape by melting and solidifying a powder bed on which a metal powder is spread
Implementation Method 2
melting and solidifying a powder bed
Implementation Method 3
thermal energy required to melt a pure copper powder cannot be obtained because a laser beam is reflected during laser irradiation
Data Source
AI summary
This invention provides a copper powder to which tin (Sn) is added such that a high-density laminated and shaped product can be obtained by a laminating and shaping method using a fiber laser as a heat source by appropriately reducing the electrical conductivity of copper, so a laminated and shaped product having a high density and a high electrical conductivity can be obtained. That is, this invention provides a copper powder for lamination shaping in which a tin element is added to pure copper. Desirably, the copper powder contains 0.5 wt % or more of the tin element. More desirably, the copper powder contains 5.0 wt % or more of the tin element. When the product has an electrical conductivity sufficient as a copper product, the copper powder desirably contains 6.0 wt % or less of the tin element. Furthermore, no element other than the tin element is desirably added to the copper powder.