Manufacturing of Hybrid Al-Cu-Heatsinks by Combining Powder Pressing with Thixoforming

Hybrid material structures allow different material properties to be combined in one single component and thus to meet high functional requirements. When manufacturing such hybrid components, particular attention must be paid to the transition zones between metallic composite partners. These transition zones need to show largely homogeneous and materially bonded structures in order to ensure ideal transmission of the material properties and to prevent component failure due to material defects. In this respect, this paper focuses on a newly developed process in which a powder metallurgical route is combined with semi-solid forming technology. Here, porous copper green bodies are inserted into a forming die and subsequently forged together with a semi-solid aluminium alloy. In this way, it was tried to combine both metal materials into a material locking or at least into a form locking manner in order to achieve ideal material properties in the final hybrid component. The aim of this paper is to find suitable process parameters to infiltrate the porous copper inlay with the semi-solid aluminium alloy during thixoforming. Therefore, different process parameters such as varying liquid fraction of the aluminium alloy and different densities of the green bodies were examined during the production of simply shaped hybrid Al-Cu-components. Afterwards the infiltration depth and produced microstructure of the components was analysed. In the future, this process allows for producing aluminium-copper hybrid heat sinks with improved heat transfer properties compared to conventional produced heat sinks.

Heat transfer enhancement at evaporation and boiling of liquid on capillary-porous surfaces created by 3D printing

The paper presents the results of experiments on measuring heat transfer in laminar-wave films of R114/R21 refrigerant mixture flowing down a vertical plate (70 × 80 mm). The experiments were carried out on the saturation line at a pressure of 2 bar. To enhance heat transfer, a porous copper coating with a flat layer thickness of 400 μm and a porosity of 45% was applied to the heat-transfer surface by 3D printing. The effectiveness of the application of the technique used for the heat transfer enhancement is demonstrated: an increase in the boiling heat transfer coefficient is obtained up to three times in comparison with the reference smooth surface, as well as two-fold increase in heat transfer coefficient in the evaporation regime. Based on the obtained experimental results and analysis of the research data of other authors, the geometric structure of promising multiscale porous enhancing coating is proposed for further research.

Porous Electrodeposited Cu as a Potential Electrode for Electrochemical Reduction Reactions of CO2

In the present study, a systematic investigation is performed to assess the relationship between electroplating parameters, pore morphology and internal surface area of copper deposits which are promising to serve as electrodes for electrochemical reduction reactions of carbon dioxide (CO2). A set of porous copper deposits are fabricated with the dynamic hydrogen bubble template method. The microstructural and Brunauer–Emmett–Teller (BET) analysis demonstrate that current density, deposition time, and bath composition control pore size, strut size, and hence surface area which could be as high as 20 m2/g. Selected sets of porous copper electrodes are then employed in the electrochemical reduction reaction test to determine their conversion performance in comparison to a monolithic copper surface. From the gas chromatography (GC) and nuclear magnetic resonance (NMR) analysis, porous copper is shown to provide higher rates of production of some important chemicals, as compared to copper foil electrodes. Porous copper with fern-like morphology serves as a promising electrode that yields relatively high amounts of acetaldehyde, acetate and ethanol. The study thus presents the opportunities to enhance the electrochemical reduction reaction of CO2 through microstructural engineering of the copper surface, which benefits both CO2 reduction and generation of chemical products of high value.

Brazing of Porous Copper Foam with Copper Sheet Using CuNiSnP Amorphous Filler Metal

This research studies effects of the brazing time on interfacial microstructure of brazed joint between the porous copper foam (PCF) and Cu substrate using CuNiSnP amorphous filler metal. To examine the interfacial microstructure and its properties, an assessment of PCF/CuNiSnP/Cu brazed joints was conducted after electric furnace brazing under hydrogen (H2) atmosphere. The results showed that the interfacial microstructure was thick for short brazing time specimens and thin for prolonged brazing time specimens. The interfacial microstructures consisted of Cu-rich solid solution, (Cu, Ni)3P, and Cu3P as a eutectic structure discovered in the brazing region at different brazing times of 5, 10, and 20 min. Only the Cu-rich solid solution and (Cu, Ni)3P were found in the specimen with brazing time of 30 min. indicating that different brazing times affected interfacial microstructures and therefore reliability of the brazed joints.