Additive manufacturing of steel-copper functionally graded material with ultrahigh bonding strength

doi:10.1016/j.jmst.2020.07.044

Abstract

Abstract:

Additive manufacturing enables processing of functionally graded materials (FGMs) with flexible spatial design and high bonding strength. A steel-copper FGM with high interfacial strength was developed using laser powder bed fusion (LPBF). The effect of laser process parameters on interfacial defects was evaluated by X-ray tomography, which indicates a low porosity level of 0.042 % therein. Gradient/fine dendritic grains in the interface are incited by high cooling rates, which facilitates interface strengthening. Multiple mechanical tests evaluate the bonding reliability of interface; and the fatigue tests further substantiate the ultrahigh bonding strength in FGMs, which is superior to traditional manufacturing methods. Mechanisms of the high interfacial bond strength were also discussed.

Key words: Laser powder bed fusion, Steel-copper multi-materials, Fatigue, Functionally graded materials, Bonding strength

Chaolin Tan, Youxiang Chew, Guijun Bi, Di Wang, Wenyou Ma, Yongqiang Yang, Kesong Zhou. Additive manufacturing of steel-copper functionally graded material with ultrahigh bonding strength[J]. J. Mater. Sci. Technol., 2021, 72: 217-222.

Figures/Tables 5

Fig. 1. (a) Schematic diagram of LPBF additive manufacturing of MS-Cu FGMs, and (b) densification behaviour evaluation by CT analysis.

Fig. 2. Interfacial microstructural analysis of FGMs through OM, SEM, and EDS: (a) OM morphology, (b) SEM morphology showing circular flows in the melt pool, (c) and (d) zoom-in images of dendrites correlative to the regions I and II in (b) respectively, and (e) EDS mapping of the interface.

Fig. 3. Interfacial EBSD and XRD analyses: (a) band contrast map and (b) inverse pole ?gure showing grain orientations, and (c) XRD patterns of the bulk copper, LPBFed MS and interface of Cu-MS FGMs.

Fig. 4. Mechanical performance of Cu-MS FGM: (a) OM image showing the morphology of indentations, (b) load-displacement curves of nano-indentation, (c) photo of the interfacial stress-concentrated non-standard tensile samples indicating fracture away from the interface, and (d) and (e) fatigue performance of the LPBFed Cu-MS FGM compared with copper and copper-steels joints in pieces of literature [[17], [18], [19], [20]]. The arrows indicate run-outs.

Table 1 Mechanical properties of the LPBF-produced Cu-MS FGMs.

Specimens	Flexural properties			Fatigue properties
	UFS (MPa)	ε (%)	σ_a (MPa₎	N_f (Cycles)	Failure position
LPBFed MS	2386 ± 41	43.3 ± 1.9	-	-	-
Bulk T2 Cu	521 ± 23	41.0 ± 5.0	45	∼2 × 10⁷ [18]	Cu
v₁-LPBFed FGM	510 ± 17	10.8 ± 0.8	45	4.167 × 10⁶	Cu (run-out)
v₂-LPBFed FGM	557 ± 19	36.6 ± 2.3	45	5.897 × 10⁶	Cu (run-out)
v₃-LPBFed FGM	364 ± 17	7.3 ± 0.7	45	0.772 × 10⁶	Interface

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