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A Layer-Dependent Analytical Model for Printability Assessment of Additive Manufacturing Copper/Steel Multi-Material

Wenqi Zhang¹, Baopeng Zhang¹, Haifeng Xiao¹

¹Wuhan National Laboratory for Optoelectronics, Huazhong University of Science and Technology, Wuhan 430074, China.

|November 27, 2021

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This study introduces an analytical model to determine optimal processing parameters for additive manufacturing of copper/steel bimetals. The model accounts for varying thermophysical properties during layer-by-layer fabrication, guiding the creation of advanced multi-material components.

Area of Science:

Materials Science
Manufacturing Engineering
Computational Modeling

Background:

Copper/steel bimetals offer combined properties of steel's strength and copper's thermal conductivity.
Additive Manufacturing (AM) is suitable for multi-material components (MMC) but faces challenges with materials having disparate thermophysical properties.
Optimal AM processing parameters vary during deposition due to property changes.

Purpose of the Study:

To develop an analytical calculation model for predicting layer-dependent processing parameters in AM of copper/steel bimetals.
To address the challenges posed by significant differences in thermophysical properties between copper and steel during AM.
To provide guidance for determining processing windows for novel multi-material components.

Main Methods:

Keywords:

additive manufacturing analytical model bimetal directed energy deposition printability maps

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An analytical model was developed to predict layer-dependent processing parameters for fabricating 07Cr15Ni5 steel on a CuCr substrate.
The model considered changes in effective thermal conductivity and specific heat capacity with layer number.
Absorption rate and catchment efficiency variations with processing parameters were incorporated.

Main Results:

The analytical model successfully predicted layer-dependent processing parameters for copper/steel bimetal fabrication.
Predicted parameter maps showed good agreement with experimental results.
The model's predictions were validated against experimental outcomes.

Conclusions:

The proposed analytical model offers new guidance for determining processing windows in additive manufacturing.
It is particularly valuable for multi-material components with significantly different physical properties.
This research facilitates the fabrication of advanced copper/steel bimetallic structures using AM.