Investigation on Optical Absorption and Reflection of Carbon Nanotubes Mixed Copper Composites for Laser Sintering Process Improvement
Selective laser sintering (SLS) of copper components manufactured via powder metallurgy is widely studied due to minimal material wastage. However, copper has poor optical absorption when exposed to infrared (IR) lasers, such as in laser-based additive manufacturing or laser surface processing. To a...
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| Format: | Article |
| Language: | English |
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MDPI AG
2023-12-01
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| Series: | Metals |
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| Online Access: | https://www.mdpi.com/2075-4701/13/12/1984 |
| _version_ | 1797380036146233344 |
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| author | Hasan Ayub Lehar Asip Khan Eanna McCarthy Inam Ul Ahad Karsten Fleischer Dermot Brabazon |
| author_facet | Hasan Ayub Lehar Asip Khan Eanna McCarthy Inam Ul Ahad Karsten Fleischer Dermot Brabazon |
| author_sort | Hasan Ayub |
| collection | DOAJ |
| description | Selective laser sintering (SLS) of copper components manufactured via powder metallurgy is widely studied due to minimal material wastage. However, copper has poor optical absorption when exposed to infrared (IR) lasers, such as in laser-based additive manufacturing or laser surface processing. To address this issue, an innovative approach to enhance the optical absorption of copper powders during infrared laser sintering is presented in this study. Carbon nanotubes (CNTs) have several unique properties, including their high surface area, plasmonic response, excellent conductivity, and optical absorption properties. CNTs were mixed with copper powders at different weight percentages using an acoustic method. The resulting Cu-CNT compositions were fabricated into pellets. The Box-Behnken Design of Experiments methodology was used to optimize the IR laser processing conditions for sintering. Spectroscopic analysis was conducted to evaluate the reflection and thermal absorption of the IR wavelengths by the Cu-CNT composites. Density and hardness measurements were taken for the laser-sintered Cu-CNT pellets. The coating of copper powders with CNTs demonstrated enhanced optical absorption and correspondingly reduced reflection. Due to the enhanced optical absorption, increased control and sensitivity of the laser sintering process was achieved, which enabled improvement in the mechanical properties of strength, hardness, and density, while also enabling control over the composite thermal expansion coefficient. A maximum average hardness of 66.5 HV was observed. Indentation test results of the samples revealed maximum tangential and radial stresses of 0.148 MPa and 0.058 Mpa, respectively. |
| first_indexed | 2024-03-08T20:31:40Z |
| format | Article |
| id | doaj.art-25e15629e0b9413c99ec51d74887a0ba |
| institution | Directory Open Access Journal |
| issn | 2075-4701 |
| language | English |
| last_indexed | 2024-03-08T20:31:40Z |
| publishDate | 2023-12-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Metals |
| spelling | doaj.art-25e15629e0b9413c99ec51d74887a0ba2023-12-22T14:24:44ZengMDPI AGMetals2075-47012023-12-011312198410.3390/met13121984Investigation on Optical Absorption and Reflection of Carbon Nanotubes Mixed Copper Composites for Laser Sintering Process ImprovementHasan Ayub0Lehar Asip Khan1Eanna McCarthy2Inam Ul Ahad3Karsten Fleischer4Dermot Brabazon5I-Form Advanced Manufacturing Research Centre, School of Mechanical and Manufacturing Engineering, Dublin City University, D09 V209 Dublin, IrelandI-Form Advanced Manufacturing Research Centre, School of Mechanical and Manufacturing Engineering, Dublin City University, D09 V209 Dublin, IrelandI-Form Advanced Manufacturing Research Centre, School of Mechanical and Manufacturing Engineering, Dublin City University, D09 V209 Dublin, IrelandI-Form Advanced Manufacturing Research Centre, School of Mechanical and Manufacturing Engineering, Dublin City University, D09 V209 Dublin, IrelandI-Form Advanced Manufacturing Research Centre, School of Mechanical and Manufacturing Engineering, Dublin City University, D09 V209 Dublin, IrelandI-Form Advanced Manufacturing Research Centre, School of Mechanical and Manufacturing Engineering, Dublin City University, D09 V209 Dublin, IrelandSelective laser sintering (SLS) of copper components manufactured via powder metallurgy is widely studied due to minimal material wastage. However, copper has poor optical absorption when exposed to infrared (IR) lasers, such as in laser-based additive manufacturing or laser surface processing. To address this issue, an innovative approach to enhance the optical absorption of copper powders during infrared laser sintering is presented in this study. Carbon nanotubes (CNTs) have several unique properties, including their high surface area, plasmonic response, excellent conductivity, and optical absorption properties. CNTs were mixed with copper powders at different weight percentages using an acoustic method. The resulting Cu-CNT compositions were fabricated into pellets. The Box-Behnken Design of Experiments methodology was used to optimize the IR laser processing conditions for sintering. Spectroscopic analysis was conducted to evaluate the reflection and thermal absorption of the IR wavelengths by the Cu-CNT composites. Density and hardness measurements were taken for the laser-sintered Cu-CNT pellets. The coating of copper powders with CNTs demonstrated enhanced optical absorption and correspondingly reduced reflection. Due to the enhanced optical absorption, increased control and sensitivity of the laser sintering process was achieved, which enabled improvement in the mechanical properties of strength, hardness, and density, while also enabling control over the composite thermal expansion coefficient. A maximum average hardness of 66.5 HV was observed. Indentation test results of the samples revealed maximum tangential and radial stresses of 0.148 MPa and 0.058 Mpa, respectively.https://www.mdpi.com/2075-4701/13/12/1984copper-CNT compositecarbon nanotubelaser sinteringthermal-electrical expansionadditive manufacturing |
| spellingShingle | Hasan Ayub Lehar Asip Khan Eanna McCarthy Inam Ul Ahad Karsten Fleischer Dermot Brabazon Investigation on Optical Absorption and Reflection of Carbon Nanotubes Mixed Copper Composites for Laser Sintering Process Improvement Metals copper-CNT composite carbon nanotube laser sintering thermal-electrical expansion additive manufacturing |
| title | Investigation on Optical Absorption and Reflection of Carbon Nanotubes Mixed Copper Composites for Laser Sintering Process Improvement |
| title_full | Investigation on Optical Absorption and Reflection of Carbon Nanotubes Mixed Copper Composites for Laser Sintering Process Improvement |
| title_fullStr | Investigation on Optical Absorption and Reflection of Carbon Nanotubes Mixed Copper Composites for Laser Sintering Process Improvement |
| title_full_unstemmed | Investigation on Optical Absorption and Reflection of Carbon Nanotubes Mixed Copper Composites for Laser Sintering Process Improvement |
| title_short | Investigation on Optical Absorption and Reflection of Carbon Nanotubes Mixed Copper Composites for Laser Sintering Process Improvement |
| title_sort | investigation on optical absorption and reflection of carbon nanotubes mixed copper composites for laser sintering process improvement |
| topic | copper-CNT composite carbon nanotube laser sintering thermal-electrical expansion additive manufacturing |
| url | https://www.mdpi.com/2075-4701/13/12/1984 |
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