The additive manufacturing of geometrically complex parts of pure copper using laser assisted powder bed fusion (LPBF) is demonstrated. The high thermal and electrical conductivity of pure copper combined with the geometric freedom of the LPBF process offers a wide range of applications. We demonstrate the fabrication of parts combining a high homogeneous density with complex geometries by adapting the laser power to the available thermal mass. This is done by applying a simple model which calculates the required laser power based on available thermal mass approximated by the local geometry.
Additive manufacturing (AM) of pure copper using laser assisted powder bed fusion (LPBF) at a wavelength of 1070 nm is demonstrated. The rapid drop of absorption at the melting point of pure copper hinders the identification of an appropriate processing window. With a combination of an extensive parameter study and a comprehensive analysis using a multiscale numerical model of the LPBF process different processing windows extending over a wide range of incident laser powers were verified. The model allows to investigate the sensitivity of single parameters, and thereby gives the opportunity to carefully adjust the strategy of the AM process.
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