Copper is used in various heating and cooling applications by exploiting its excellent thermal and electrical conductivities. Powder- and laser-based additive manufacturing (AM) of pure copper is challenging as it encounters porosity because of its low absorptivity. The present research reports the feasibility of cold metal transfer-based wire arc additive manufacturing (CMT-WAAM) for the manufacturing of pure copper thin wall. The microstructure of the deposit is examined at three distinct locations. The mechanical properties (including ultimate tensile strength, yield strength, elongation and hardness) are examined in both scanning direction (SD) and build direction (BD). The thermal and electrical properties of the deposit are also measured. The deposited thin wall is reported to be firm and straight without any bulging and collapsing. The CMT-WAAM fabricated pure Cu samples exhibit superior tensile strength (310 ± 12 MPa in SD and 265 ± 9 in BD) than all other AM techniques. The thermal and electrical conductivities of the built copper wall are comparable to the previously reported conductivities of pure copper fabricated by other AM routes.
DebRoyTWeiHLZubackJS, et al.Additive manufacturing of metallic components – process, structure and properties. Prog Mater Sci2018; 92: 112–224.
2.
WangZBeeseAM. Stress state-dependent mechanics of additively manufactured 304L stainless steel: part 1 – characterization and modeling of the effect of stress state and texture on microstructural evolution. Mater Sci Eng A2019; 743: 811–823.
3.
LeirmoJLBaturynskaI. Challenges and proposed solutions for aluminium in laser powder bed fusion. Procedia CIRP2020; 93: 114–119.
4.
Al-RubaieKSMelottiSRabeloA, et al.Machinability of SLM-produced Ti6Al4V titanium alloy parts. J Manuf Process2020; 57: 768–786.
5.
ShivaSPalaniIAMishraSK, et al.Investigations on the influence of composition in the development of Ni–Ti shape memory alloy using laser based additive manufacturing. Opt Laser Technol2015; 69: 44–51.
6.
AgarwalR. The personal protective equipment fabricated via 3D printing technology during COVID-19. Ann 3D Print Med2022; 5: 100042.
7.
AgarwalRMalhotraSGuptaV, et al.The application of three-dimensional printing on foot fractures and deformities: a mini-review. Ann 3D Print Med2022; 5: 100046.
8.
AgarwalRGuptaVSinghJ. Additive manufacturing-based design approaches and challenges for orthopaedic bone screws: a state-of-the-art review. J Braz Soc Mech Sci2022; 44: 37.
9.
AgarwalRMalhotraSGuptaV, et al.Three–dimensional printing of triply periodic minimal surface structured scaffolds for load–bearing bone defects. Polym Eng Sci2023; 63: 972–985.
10.
LykovPASafonovEVAkhmedianovAM. Selective laser melting of copper. Mater Sci Forum2016; 843: 284–288.
11.
TranTQChinnappanALeeJKY, et al.3D printing of highly pure copper. Metals (Basel)2019; 9: 756.
12.
KoichiMHopkinsDW. Analysis of Welded Structures. First ed. London: Pergamon Press, 1980, p.80.
13.
SingerFDeisenrothDCHymasDM, et al. Additively manufactured copper components and composite structures for thermal management applications. In: 2017 16th IEEE Intersociety Conference on Thermal and Thermomechanical Phenomena in Electronic Systems (ITherm). IEEE, pp. 174–183.
14.
CongBOuyangRQiB, et al.Influence of cold metal transfer process and its heat input on weld bead geometry and porosity of aluminum-copper alloy welds. Rare Met Mater Eng2016; 45: 606–611.
15.
YadavSPaulCPJinoopAN, et al.Laser directed energy deposition based additive manufacturing of copper: process development and material characterizations. J Manuf Process2020; 58: 984–997.
16.
TomarBShivaSNathT. A review on wire arc additive manufacturing: processing parameters, defects, quality improvement and recent advances. Mater Today Commun2022; 31: 103739.
17.
DongBPanZShenC, et al.Fabrication of copper-rich Cu-Al alloy using the wire-arc additive manufacturing process. Metall Mater Trans B2017; 48: 3143–3151.
18.
DeshmukhPSTomarKSathiarajGD, et al.Optimum strength and ductility of pure copper fabricated by wire arc additive manufacturing. Manuf Lett2022; 33: 24–28.
19.
BabyJAmirthalingamM. Microstructural development during wire arc additive manufacturing of copper-based components. Weld World2020; 64: 395–405.
20.
FurukawaK. New CMT arc welding process – welding of steel to aluminium dissimilar metals and welding of super-thin aluminium sheets. Weld Int2006; 20: 440–445.
21.
PickinCGYoungK. Evaluation of cold metal transfer (CMT) process for welding aluminium alloy. Sci Technol Weld Join2006; 11: 583–585.
22.
TomarB. Fatigue analyses of GMAW welds of thermo-mechanically processed 700MC ultra high strength steel. IJRESM2020; 3: 220–225.
23.
SunZLvYXuB, et al.Investigation of droplet transfer behaviours in cold metal transfer (CMT) process on welding Ti-6Al-4V alloy. Int J Adv Manuf Technol2015; 80: 2007–2014.
24.
FangXZhangLChenG, et al.Correlations between microstructure characteristics and mechanical properties in 5183 aluminium alloy fabricated by wire-arc additive manufacturing with different arc modes. Materials (Basel)2018; 11: 2075.
25.
CongBQiZQiB, et al.A comparative study of additively manufactured thin wall and block structure with Al-6.3%Cu alloy using cold metal transfer process. Appl Sci2017; 7: 75.
26.
SelviSVishvaksenanARajasekarE. Cold metal transfer (CMT) technology - an overview. Def Technol2018; 14: 28–44.
27.
WangPZhangHZhuH, et al.Wire-arc additive manufacturing of AZ31 magnesium alloy fabricated by cold metal transfer heat source: processing, microstructure, and mechanical behavior. J Mater Process Technol2021; 288: 116895.
28.
PalKPalSK. Effect of pulse parameters on weld quality in pulsed gas metal arc welding: a review. J Mater Eng Perform2011; 20: 918–931.
29.
StinsonHWardRQuinnJ, et al.Comparison of properties and bead geometry in MIG and CMT single layer samples for WAAM applications. Metals (Basel)2021; 11: 1530.
30.
DerekarKSAddisonAJoshiSS, et al.Effect of pulsed metal inert gas (pulsed-MIG) and cold metal transfer (CMT) techniques on hydrogen dissolution in wire arc additive manufacturing (WAAM) of aluminium. Int J Adv Manuf Technol2020; 107: 311–331.
31.
MezragBDeschaux-BeaumeFBenachourM. Control of mass and heat transfer for steel/aluminium joining using cold metal transfer process. Sci Technol Weld Join2015; 20: 189–198.
Salavati-NiasariMDavarF. Synthesis of copper and copper(I) oxide nanoparticles by thermal decomposition of a new precursor. Mater Lett2009; 63: 441–443.
34.
KumarMDBManikandanM. Evaluation of microstructure, residual stress, and mechanical properties in different planes of wire + arc additive manufactured nickel-based superalloy. Met Mater Int2022; 28: 3033–3056.
35.
OuWKnappGLMukherjeeT, et al.An improved heat transfer and fluid flow model of wire-arc additive manufacturing. Int J Heat Mass Transf2021; 167: 120835.
36.
ChakrabartiDDavisCStrangwoodM. Characterisation of bimodal grain structures in HSLA steels. Mater Charact2007; 58: 423–438.
37.
OuWMukherjeeTKnappGL, et al.Fusion zone geometries, cooling rates and solidification parameters during wire arc additive manufacturing. Int J Heat Mass Transf2018; 127: 1084–1094.
38.
TomarBShivaS. Microstructure evolution in steel/copper graded deposition prepared using wire arc additive manufacturing. Mater Lett2022; 328: 133217.
39.
ZhaoDQianXGuX, et al.Measurement techniques for thermal conductivity and interfacial thermal conductance of bulk and thin film materials. J Electron Packag2016; 138: 040802.
40.
ZhangXSunCPanT, et al.Additive manufacturing of copper – H13 tool steel bi-metallic structures via Ni-based multi-interlayer. Addit Manuf2020; 36: 101474.
41.
FrigolaP, et al.Fabricating copper components. Adv Mater Process2014; 172: 20–24.
42.
WilliamsS. W., et al., Wire and arc additive manufacturing of highly conductive pure copper, RAPDASA2019.
43.
GuschlbauerRMomeniSOsmanlicF, et al.Process development of 99.95% pure copper processed via selective electron beam melting and its mechanical and physical properties. Mater Charact2018; 143: 163–170.
