Forum for Science, Industry and Business

Sponsored by:     3M 
Search our Site:

 

Components made from copper powder open up new opportunities

16.02.2011
Up to now it was not possible to use Selective Laser Melting (SLM) on copper alloys. Now, however, research scientists at the Fraunhofer Institute for Laser Technology ILT have solved the technical problems that prevented this by enhancing the technique. The new method opens up new possibilities, for instance in plastics processing.

Rapid Manufacturing is making triumphant progress in industrial production as it enables digitized design engineering data to be directly and quickly translated into workpieces. In this context, SLM is particularly suitable for producing metal components of complex shapes which cannot be manufactured using conventional technology or can only be produced at very high cost.


Tool insert with internal cooling channels made of Hovadur (R) K220 produced using the SLM technique. Fraunhofer Institute for Laser Technology ILT, Aachen

In the InnoSurface project, which is funded by the German Federal Ministry of Economics and Technology (BMWi), a research team at Fraunhofer ILT in Aachen has succeeded in modifying the SLM process to make it suitable for copper materials. This opens up new opportunities, for example in the manufacture of tools for plastics processing.

In SLM the workpiece is built up layer by layer on a platform from powder material. Basically, the process functions like a printer working in three dimensions. Directed by the computer-generated design data for the planned workpiece, the metal powder is deposited in layers and then melted at the required points by a laser beam. As a result, it bonds with the already produced part of the object. Material tests have shown that steel or light-metal components produced in this way exhibit the same mechanical properties as conventionally produced parts.

Owing to the high thermal conductivity of copper and copper alloys, however, it has not been possible up to now to use SLM on these materials. Although copper has a lower melting point than steel, it also exhibits lower laser light absorption and higher heat dissipation. As a result, the melting track interupts and tiny balls of molten metal form. This creates cavities and thus reduces the density of the component. »To compensate for the high heat dissipation and the low laser light absorption by the copper during the melting process, we use a 1000-watt laser instead of the 200-watt laser that is currently the norm in SLM,« explains project manager David Becker. To achieve satisfactory results, he chose a laser that produces a particularly even beam profile. Meanwhile Becker and his team modified the entire installation to prevent the high energy input from causing disruptions. For example, they changed the inert gas control system and the mechanical equipment. »Tests with the copper alloy Hovadur K220 are already showing excellent results,« Becker continues, »with workpiece density reaching almost 100 percent.« The technique is therefore ready for industrial use.

It is the high thermal conductivity of copper and its alloys that makes them suitable for many applications. Inserts of these materials in steel injection molding tools for the manufacture of plastic parts ensure rapid heat removal at critical points. SLM makes it possible to integrate conformal cooling channels in these copper inserts to carry a coolant such as water. Cycle times and warping are reduced by fast and even cooling of the entire tool.

In the near future the Aachen-based research scientists intend to go a step further and process not only copper alloys but also pure copper to make dense components. The thermal conductivity of pure copper is almost twice as high as Hovadur K220. This makes for an interesting challenge!

Contacts at Fraunhofer ILT
If you have any questions our experts will be pleased to assist:
David Becker
Rapid Manufacturing
Phone +49 241 8906-568
david.becker@ilt.fraunhofer.de
Dr. Konrad Wissenbach
Additive Manufacturing and Functional Layers
Phone +49 241 8906-147
konrad.wissenbach@ilt.fraunhofer.de
Fraunhofer Institute for Laser Technology ILT
Steinbachstrasse 15
52074 Aachen
Phone +49 241 8906-0
Fax +49 241 8906-121

Axel Bauer | Fraunhofer-Institut
Further information:
http://www.ilt.fraunhofer.de

More articles from Process Engineering:

nachricht Fraunhofer researchers develop measuring system for ZF factory in Saarbrücken
21.11.2017 | Fraunhofer-Institut für Zerstörungsfreie Prüfverfahren IZFP

nachricht New manufacturing process for SiC power devices opens market to more competition
14.09.2017 | North Carolina State University

All articles from Process Engineering >>>

The most recent press releases about innovation >>>

Die letzten 5 Focus-News des innovations-reports im Überblick:

Im Focus: Nanoparticles help with malaria diagnosis – new rapid test in development

The WHO reports an estimated 429,000 malaria deaths each year. The disease mostly affects tropical and subtropical regions and in particular the African continent. The Fraunhofer Institute for Silicate Research ISC teamed up with the Fraunhofer Institute for Molecular Biology and Applied Ecology IME and the Institute of Tropical Medicine at the University of Tübingen for a new test method to detect malaria parasites in blood. The idea of the research project “NanoFRET” is to develop a highly sensitive and reliable rapid diagnostic test so that patient treatment can begin as early as possible.

Malaria is caused by parasites transmitted by mosquito bite. The most dangerous form of malaria is malaria tropica. Left untreated, it is fatal in most cases....

Im Focus: A “cosmic snake” reveals the structure of remote galaxies

The formation of stars in distant galaxies is still largely unexplored. For the first time, astron-omers at the University of Geneva have now been able to closely observe a star system six billion light-years away. In doing so, they are confirming earlier simulations made by the University of Zurich. One special effect is made possible by the multiple reflections of images that run through the cosmos like a snake.

Today, astronomers have a pretty accurate idea of how stars were formed in the recent cosmic past. But do these laws also apply to older galaxies? For around a...

Im Focus: Visual intelligence is not the same as IQ

Just because someone is smart and well-motivated doesn't mean he or she can learn the visual skills needed to excel at tasks like matching fingerprints, interpreting medical X-rays, keeping track of aircraft on radar displays or forensic face matching.

That is the implication of a new study which shows for the first time that there is a broad range of differences in people's visual ability and that these...

Im Focus: Novel Nano-CT device creates high-resolution 3D-X-rays of tiny velvet worm legs

Computer Tomography (CT) is a standard procedure in hospitals, but so far, the technology has not been suitable for imaging extremely small objects. In PNAS, a team from the Technical University of Munich (TUM) describes a Nano-CT device that creates three-dimensional x-ray images at resolutions up to 100 nanometers. The first test application: Together with colleagues from the University of Kassel and Helmholtz-Zentrum Geesthacht the researchers analyzed the locomotory system of a velvet worm.

During a CT analysis, the object under investigation is x-rayed and a detector measures the respective amount of radiation absorbed from various angles....

Im Focus: Researchers Develop Data Bus for Quantum Computer

The quantum world is fragile; error correction codes are needed to protect the information stored in a quantum object from the deteriorating effects of noise. Quantum physicists in Innsbruck have developed a protocol to pass quantum information between differently encoded building blocks of a future quantum computer, such as processors and memories. Scientists may use this protocol in the future to build a data bus for quantum computers. The researchers have published their work in the journal Nature Communications.

Future quantum computers will be able to solve problems where conventional computers fail today. We are still far away from any large-scale implementation,...

All Focus news of the innovation-report >>>

Anzeige

Anzeige

Event News

Ecology Across Borders: International conference brings together 1,500 ecologists

15.11.2017 | Event News

Road into laboratory: Users discuss biaxial fatigue-testing for car and truck wheel

15.11.2017 | Event News

#Berlin5GWeek: The right network for Industry 4.0

30.10.2017 | Event News

 
Latest News

Previous evidence of water on mars now identified as grainflows

21.11.2017 | Physics and Astronomy

NASA's James Webb Space Telescope completes final cryogenic testing

21.11.2017 | Physics and Astronomy

New catalyst controls activation of a carbon-hydrogen bond

21.11.2017 | Life Sciences

VideoLinks
B2B-VideoLinks
More VideoLinks >>>