journal article·2025-02-14

Investigation of additive manufacturing based direct ink writing of aluminium–copper alloys

A. Anbarasan, K. Kanthavel, M. Sakthivel

Journal of Materials Research· Volume 40· Issue 3
Publisher page

Abstract

This additive manufacturing (AM) work is focused on developing a new combination of aluminium–copper (Al–Cu) alloys using direct ink writing (DIW) methods for automotive, aerospace, and electrical industry components. The combination of adding Cu in Al at various percentages ranging from 20 to 80% is applied in this work to evaluate the synergistic properties. The microstructure, mechanical properties, and chemical composition of the thermally post-processed parts were studied by Vickers microhardness, X-ray diffraction (XRD), optical microscope, and scanning electron microscope (SEM) with energy dispersive X-ray analysis (EDX). The investigation reveals that the mechanical property, microstructure, and chemical composition depend upon the physical inclusions of Cu with Al. Our results show that 40% Cu composition possesses crucial traits like the hardness of 656 HV due to the formation of AlCu intermetallics without any unwanted oxides.Graphical abstract
Source: expertdata · Quality: candidate unverified · Source record ↗

Research context

OpenAlex topics: Additive Manufacturing and 3D Printing Technologies · Additive Manufacturing Materials and Processes · Material Properties and Applications

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

References (22)

Show source-provided references
1. T.J. Ober, D. Foresti, J.A. Lewis, Active mixing of complex fluids at the microscale. Proc. Natl. Acad. Sci. U S A 112(40), 12293–12298 (2015). https://doi.org/10.1073/pnas.150922411210.1073/pnas.1509224112 ↗
2. K. Narita, M.A. Saccone, Y. Sun, J.R. Greer, Additive manufacturing of 3D batteries: a perspective. J. Mater. Res. 37(9), 1535–1546 (2022). https://doi.org/10.1557/s43578-022-00562-w10.1557/s43578-022-00562-w ↗
3. J.G. Diwei Zhang, C. Chu, S. Ma, Y. Wang, C. Duan, A.S. Xiaolu Shi, X. Gaojie, Y. Cheng, A novel method to avoid the sintering shrinkage of Al2O3-Cr cermets formed by direct ink writing. J. Alloys Compd. (2005). https://doi.org/10.1016/j.jallcom.2005.05.00210.1016/j.jallcom.2005.05.002 ↗
4. S.S. Li et al., Development and applications of aluminum alloys for aerospace industry. J. Market. Res. 27, 944–983 (2023). https://doi.org/10.1016/j.jmrt.2023.09.27410.1016/j.jmrt.2023.09.274 ↗
5. Q. Mao, Y. Liu, Y. Zhao, A review on copper alloys with high strength and high electrical conductivity. J. Alloys Compd. (2024). https://doi.org/10.1016/j.jallcom.2024.17445610.1016/j.jallcom.2024.174456 ↗
6. P.A. Rometsch, Y. Zhu, X. Wu, A. Huang, Review of high-strength aluminium alloys for additive manufacturing by laser powder bed fusion. Mater. Des. 219, 110779 (2022). https://doi.org/10.1016/j.matdes.2022.11077910.1016/j.matdes.2022.110779 ↗
7. J.M. Ortega et al., Active mixing of disparate inks for multimaterial 3D printing. Adv. Mater. Technol. 4(7), 1–13 (2019). https://doi.org/10.1002/admt.20180071710.1002/admt.201800717 ↗
8. A.M. Golobic et al., Active mixing of reactive materials for 3D printing. Adv. Eng. Mater. 1900147, 1–7 (2019). https://doi.org/10.1002/adem.20190014710.1002/adem.201900147 ↗
9. R. Dylla-Spears et al., 3D printed gradient index glass optics. Sci. Adv. 6(47), 1–8 (2020). https://doi.org/10.1126/sciadv.abc742910.1126/sciadv.abc7429 ↗
10. J.S. Pelz, N. Ku, W.T. Shoulders, M.A. Meyers, L.R. Vargas-Gonzalez, Multi-material additive manufacturing of functionally graded carbide ceramics via active, in-line mixing. Addit. Manuf. (2021). https://doi.org/10.1016/j.addma.2020.10164710.1016/j.addma.2020.101647 ↗
11. K. Rajasekhar, V. Suresh Babu, M.J. Davidson, Microstructural and mechanical properties of Al–Cu functionally graded materials fabricated by powder metallurgy method. Mater. Today 41, 1156–1159 (2019). https://doi.org/10.1016/j.matpr.2020.09.15710.1016/j.matpr.2020.09.157 ↗
12. T. Liu, Q. Wang, Y. Sui, Q. Wang, W. Ding, An investigation into interface formation and mechanical properties of aluminium–copper bimetal by squeeze casting. Mater. Des. 89, 1137–1146 (2016). https://doi.org/10.1016/j.matdes.2015.10.07210.1016/j.matdes.2015.10.072 ↗
13. X. Wang, C. Gu, Y. Zheng, Z. Shen, H. Liu, Laser shock welding of aluminum/aluminum and aluminum/copper plates. Mater. Des. 56, 26–30 (2014). https://doi.org/10.1016/j.matdes.2013.10.09110.1016/j.matdes.2013.10.091 ↗
14. P. Gao, Y. Zhang, K.P. Mehta, Metallurgical and mechanical properties of Al–Cu Joint by friction stir spot welding and modified friction stir clinching. Met. Mater. Int. 27(8), 3085–3094 (2021). https://doi.org/10.1007/s12540-020-00759-w10.1007/s12540-020-00759-w ↗
15. A. Abdollah-Zadeh, T. Saeid, B. Sazgari, Microstructural and mechanical properties of friction stir welded aluminum/copper lap joints. J. Alloy. Compd. 460(1–2), 535–538 (2008). https://doi.org/10.1016/j.jallcom.2007.06.00910.1016/j.jallcom.2007.06.009 ↗
16. T. Saeid, A. Abdollah-zadeh, B. Sazgari, Weldability and mechanical properties of dissimilar aluminium–copper lap joints made by friction stir welding. J. Alloy. Compd. 490(1–2), 652–655 (2010). https://doi.org/10.1016/j.jallcom.2009.10.12710.1016/j.jallcom.2009.10.127 ↗
17. K. Liu, H. Yu, X. Li, S. Wu, Study on diffusion characteristics of Al–Cu systems and mechanical properties of intermetallics. J. Alloy. Compd. 874, 159831 (2021). https://doi.org/10.1016/j.jallcom.2021.15983110.1016/j.jallcom.2021.159831 ↗
18. J. Yu, G. Wang, Y. Rong, Experimental study on the surface integrity and chip formation in the micro cutting process. Procedia Manuf. 1, 655–662 (2015). https://doi.org/10.1016/j.promfg.2015.09.06310.1016/j.promfg.2015.09.063 ↗
19. X. Xu et al., Effect of Mn content on microstructure and properties of 6000 series aluminum alloy. Appl. Phys. A Mater. Sci. Process. 125(8), 1–9 (2019). https://doi.org/10.1007/s00339-019-2780-910.1007/s00339-019-2780-9 ↗
20. M. Eslami, F. Golestani-fard, H. Saghafian, A. Robin, Study on tribological behavior of electrodeposited Cu-Si3N4 composite coatings. Mater. Design 58, 557–569 (2014). https://doi.org/10.1016/j.matdes.2014.02.03010.1016/j.matdes.2014.02.030 ↗
21. M.C. Şenel, M. Gürbüz, Investigation on mechanical properties and microstructures of aluminum hybrid composites reinforced with Al2O3/GNPs binary particles. Arch. Metall. Mater. 66(1), 97–106 (2021). https://doi.org/10.24425/amm.2021.13476410.24425/amm.2021.134764 ↗
22. F. Nazeer et al., Effect of processing routes on mechanical and thermal properties of copper–graphene composites. Mater. Sci. Technol. (UK) 35(14), 1770–1774 (2019). https://doi.org/10.1080/02670836.2019.164696210.1080/02670836.2019.1646962 ↗