RESUMEN
The processing of pure copper (Cu) has been a challenge for laser-based additive manufacturing for many years since copper powders have a high reflectivity of up to 83% of electromagnetic radiation at a wavelength of 1070 nm. In this study, Cu particles were coated with sub-micrometer tungsten (W) particles to increase the laser beam absorptivity. The coated powders were processed by powder bed fusion-laser beam for metals (PBF-LB/M) with a conventional laser system of <300 watts laser power and a wavelength of 1070 nm. Two different powder manufacturing routes were developed. The first manufacturing route was gas atomization combined with a milling process by a planetary mill. The second manufacturing method was gas atomization with particle co-injection, where a separate W particle jet was sprayed into the atomized Cu jet. As part of the investigations, an extensive characterization of powder and additively manufactured test specimens was carried out. The specimens of Cu/W powders manufactured by the milling process have shown superior results. The laser absorptivity of the Cu/W powder was increased from 22.5% (pure Cu powder) to up to 71.6% for powders with 3 vol% W. In addition, a relative density of test specimens up to 98.2% (optically) and 95.6% (Archimedes) was reached. Furthermore, thermal conductivity was measured by laser flash analysis (LFA) and thermo-optical measurement (TOM). By using eddy current measurement, the electrical conductivity was analyzed. In comparison to the Cu reference, a thermal conductivity of 88.9% and an electrical conductivity of 85.8% were determined. Moreover, the Vickers hardness was measured. The effect of porosity on conductivity properties and hardness was investigated and showed a linear correlation. Finally, a demonstrator was built in which a wall thickness of down to 200 µm was achieved. This demonstrates that the Cu/W composite can be used for heat exchangers, heat sinks, and coils.
RESUMEN
Two data evaluation concepts for X-ray stress analysis based on energy-dispersive diffraction on polycrystalline materials with cubic crystal structure, almost random crystallographic texture and strong single-crystal elastic anisotropy are subjected to comparative assessment. The aim is the study of the residual stress state in hard-to-reach measurement points, for which the sin2ψ method is not applicable due to beam shadowing at larger sample tilting. This makes the approaches attractive for stress analysis in engineering parts with complex shapes, for example. Both approaches are based on the assumption of a biaxial stress state within the irradiated sample volume. They exploit in different ways the elastic anisotropy of individual crystallites acting at the microscopic scale and the anisotropy imposed on the material by the near-surface stress state at the macroscopic scale. They therefore complement each other, in terms of both their preconditions and their results. The first approach is based on the evaluation of strain differences, which makes it less sensitive to variations in the strain-free lattice parameter a 0. Since it assumes a homogeneous stress state within the irradiated sample volume, it provides an average value of the in-plane stresses. The second approach exploits the sensitivity of the lattice strain to changes in a 0. Consequently, it assumes a homogeneous chemical composition but provides a stress profile within the information depth. Experimental examples from different fields in materials science, namely shot peening of austenitic steel and in situ stress analysis during welding, are presented to demonstrate the suitability of the proposed methods.