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High absorptivity nanotextured powders for additive manufacturing
Ottman A Tertuliano1,2, Philip J DePond2,3, Andrew C Lee4
1Mechanical Engineering and Applied Mechanics, University of Pennsylvania, 220 S. 33rd St., Philadelphia, PA 19104, USA.
Science Advances
|September 4, 2024
Summary
Researchers developed a method to add nanoscale grooves to metal powders, boosting absorptivity by 70% for laser powder bed fusion. This innovation enhances energy-efficient manufacturing of metals like copper and tungsten.
Area of Science:
- Materials Science
- Manufacturing Engineering
- Nanotechnology
Background:
- Metal additive manufacturing (AM) faces limitations due to poor control over energy source-material interactions.
- High reflectivity of certain metal powders, like copper and tungsten, hinders efficient laser absorption during AM processes.
Purpose of the Study:
- To develop a generalizable surface modification technique for metal powders to enhance laser absorptivity.
- To enable energy-efficient additive manufacturing of reflective and refractory metals.
Main Methods:
- Introduction of nanoscale grooves onto the surface of metal powders.
- Utilizing laser powder bed fusion (LPBF) to assess the impact of surface modification on absorptivity and printability.
- Employing simulations to understand the physical mechanisms behind enhanced absorptivity.
Main Results:
- Achieved up to 70% increase in powder absorptivity for copper, copper-silver, and tungsten.
- Enabled printing of pure copper with relative densities up to 92% at low laser energy densities (83 J/mm³).
- Simulations confirmed that nanoscale grooves enhance absorptivity through plasmonic effects and multiple scattering.
Conclusions:
- Surface modification via nanoscale grooving is a generalizable method to improve metal powder absorptivity and printability.
- This approach overcomes limitations in manufacturing reflective and refractory metals using AM.
- The developed process offers a pathway to more energy-efficient metal additive manufacturing.
