scholarly journals Laser powder bed fusion additive manufacturing of copper wicking structures: fabrication and capillary characterization

2021 ◽  
Author(s):  
Adnen Mezghani
Keyword(s):  
Additive Manufacturing ◽  
Performance Analysis ◽  
Heat Pipes ◽  
Manufacturing Processes ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Published Report ◽  
Secondary Manufacturing ◽  
Design Freedom

PurposeAn integral component in heat pipes (HPs) and vapor chambers (VCs) is a porous wicking structure. Traditional methods for manufacturing wicking structures within HPs and VCs involve secondary manufacturing processes and are generally limited to simple geometries. This work aims to leverage the unprecedented level of design freedom of laser powder bed fusion (LPBF) additive manufacturing (AM) to produce integrated wicking structures for HPs and VCs.Design/methodology/approachCopper wicking structures are fabricated through LPBF via partial sintering and via the formation of square, hexagonal and rectangular arrangements of micro-pins and micro-grooves, produced in multiple build directions. Wicks are characterized by conducting capillary performance analysis through the measurement of porosity, permeability and capillary rate-of-rise.FindingsCopper wicking structures were successfully fabricated with capillary performance, K/reff, ranging from 0.186–1.74 µm. The rectangular-arrangement micro-pin wick presented the highest performance.Originality/valueThis work represents the first published report on LPBF AM of copper wicking structures for HPs/VCs applications and represents foundational knowledge for fabricating complete assemblies of copper VCs and HPs through LPBF AM.

scholarly journals Laser powder bed fusion additive manufacturing of copper wicking structures: fabrication and capillary characterization

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Adnen Mezghani ◽  
Abdalla R. Nassar ◽  
Corey J. Dickman ◽  
Eduardo Valdes ◽  
Raul Alvarado
Keyword(s):  
Additive Manufacturing ◽  
Design Methodology ◽  
Heat Pipes ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Content Type ◽  
Powder Bed ◽  
Published Report ◽  
Secondary Manufacturing ◽  
Design Freedom

Purpose An integral component in heat pipes (HPs) and vapor chambers (VCs) is a porous wicking structure. Traditional methods for manufacturing wicking structures within HPs and VCs involve secondary manufacturing processes and are generally limited to simple geometries. This work aims to leverage the unprecedented level of design freedom of laser powder bed fusion (LPBF) additive manufacturing (AM) to produce integrated wicking structures for HPs and VCs. Design/methodology/approach Copper wicking structures are fabricated through LPBF via partial sintering and via the formation of square, hexagonal and rectangular arrangements of micro-pins and micro-grooves, produced in multiple build directions. Wicks are characterized by conducting capillary performance analysis through the measurement of porosity, permeability and capillary rate-of-rise. Findings Copper wicking structures were successfully fabricated with capillary performance, K/reff, ranging from 0.186–1.74 µm. The rectangular-arrangement micro-pin wick presented the highest performance. Originality/value This work represents the first published report on LPBF AM of copper wicking structures for HPs/VCs applications and represents foundational knowledge for fabricating complete assemblies of copper VCs and HPs through LPBF AM.

scholarly journals Analysis of the Porous Structures from Laser Powder Bed Fusion Additive Manufacturing

2021 ◽  
Author(s):  
Chang Jiang Wang ◽  
Kevin Hazlehurst ◽  
Arun Arjunan ◽  
Lida Shen
Keyword(s):  
Finite Element ◽  
Additive Manufacturing ◽  
Bone Ingrowth ◽  
Manufacturing Processes ◽  
Powder Bed Fusion ◽  
Porous Structures ◽  
Laser Powder Bed Fusion ◽  
Stress Concentrations ◽  
Powder Bed ◽  
Internal Surfaces

Open and closed porous structures with lattice and honeycomb geometry can be built using laser powder bed fusion additive manufacturing processes. The porous structures can be used to tailor the mechanical properties of a component or provide other functionality, such as for bone ingrowth in medical implants. Porous structures were created and analysed in this paper both physically and using finite element modelling. It was found that the accuracy of the built parts was reasonable and within the manufacturing processes general tolerance of +/- 50 μm. However, it was noticeable that the corners of the square shape pores were naturally filleted by the manufacturing process. The finite element model was developed using ANSYS software, stress concentrations were observed in the porous structures under loading. In addition to this, fragments of the material were present on the internal surfaces of the pores, which were formed from partially melted powder particles.

scholarly journals An instrument for in situ time-resolved X-ray imaging and diffraction of laser powder bed fusion additive manufacturing processes

2018 ◽  
Vol 89 (5) ◽  
pp. 055101 ◽  
Author(s):  
Nicholas P. Calta ◽  
Jenny Wang ◽  
Andrew M. Kiss ◽  
Aiden A. Martin ◽  
Philip J. Depond ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Processes ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Time Resolved ◽  
Powder Bed ◽  
X Ray ◽  
X Ray Imaging

scholarly journals GEOMETRICAL BENCHMARKING OF LASER POWDER BED FUSION SYSTEMS BASED ON DESIGNER NEEDS

2021 ◽  
Vol 1 ◽  
pp. 1657-1666
Author(s):  
Joaquin Montero ◽  
Sebastian Weber ◽  
Christoph Petroll ◽  
Stefan Brenner ◽  
Matthias Bleckmann ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Use Case ◽  
Powder Bed Fusion ◽  
Design For Additive Manufacturing ◽  
Laser Powder Bed Fusion ◽  
Measuring Systems ◽  
Powder Bed ◽  
Geometric Dimensioning And Tolerancing ◽  
Uncertainty Map ◽  
New System

AbstractCommercially available metal Laser Powder Bed Fusion (L-PBF) systems are steadily evolving. Thus, design limitations narrow and the diversity of achievable geometries widens. This progress leads researchers to create innovative benchmarks to understand the new system capabilities. Thereby, designers can update their knowledge base in design for additive manufacturing (DfAM). To date, there are plenty of geometrical benchmarks that seek to develop generic test artefacts. Still, they are often complex to measure, and the information they deliver may not be relevant to some designers. This article proposes a geometrical benchmarking approach for metal L-PBF systems based on the designer needs. Furthermore, Geometric Dimensioning and Tolerancing (GD&T) characteristics enhance the approach. A practical use-case is presented, consisting of developing, manufacturing, and measuring a meaningful and straightforward geometric test artefact. Moreover, optical measuring systems are used to create a tailored uncertainty map for benchmarking two different L-PBF systems.

scholarly journals Gold, Silver, and Electrum Electroless Plating on Additively Manufactured Laser Powder-Bed Fusion AlSi10Mg Parts: A Review

Coatings ◽  
2021 ◽  
Vol 11 (4) ◽  
pp. 422
Author(s):  
Dana Ashkenazi ◽  
Alexandra Inberg ◽  
Yosi Shacham-Diamand ◽  
Adin Stern
Keyword(s):  
Additive Manufacturing ◽  
Low Cost ◽  
Ion Beam ◽  
Surface Finishing ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Finishing Process ◽  
Gold Silver ◽  
3D Printed

Additive manufacturing (AM) revolutionary technologies open new opportunities and challenges. They allow low-cost manufacturing of parts with complex geometries and short time-to-market of products that can be exclusively customized. Additive manufactured parts often need post-printing surface modification. This study aims to review novel environmental-friendly surface finishing process of 3D-printed AlSi10Mg parts by electroless deposition of gold, silver, and gold–silver alloy (e.g., electrum) and to propose a full process methodology suitable for effective metallization. This deposition technique is simple and low cost method, allowing the metallization of both conductive and insulating materials. The AlSi10Mg parts were produced by the additive manufacturing laser powder bed fusion (AM-LPBF) process. Gold, silver, and their alloys were chosen as coatings due to their esthetic appearance, good corrosion resistance, and excellent electrical and thermal conductivity. The metals were deposited on 3D-printed disk-shaped specimens at 80 and 90 °C using a dedicated surface activation method where special functionalization of the printed AlSi10Mg was performed to assure a uniform catalytic surface yielding a good adhesion of the deposited metal to the substrate. Various methods were used to examine the coating quality, including light microscopy, optical profilometry, XRD, X-ray fluorescence, SEM–energy-dispersive spectroscopy (EDS), focused ion beam (FIB)-SEM, and XPS analyses. The results indicate that the developed coatings yield satisfactory quality, and the suggested surface finishing process can be used for many AM products and applications.

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