Wire electron beam additive manufacturing of copper

Abstract

Abstract The potential of additive manufacturing of copper components is not yet sufficiently investigated despite the existence of a large market for copper products, especially in the energy, mobility, and aerospace sectors. Wire arc additive manufacturing (WAAM) and laser directed energy deposition (DED) with conventional lasers, the latter due to the high light reflection in copper, have difficulties in the additive manufacturing of this material. The electron beam, on the other hand, achieves a high energy input even with copper and thus the desired efficiency. Wire electron beam additive manufacturing (WEBAM) is capable to produce pore free copper components with high deposition rates in the range of 2 kg/h. The microstructure of pure copper WEBAM parts exhibits large, elongated grains growing epitaxially and additional structures related to the layered approach specific for additive manufacturing. The company pro-beam additive GmbH investigates several applications required by different markets. As an example, for the aerospace industry a model for a rocket motor (650 mm height, 295 mm maximum diameter, 22 kg weight) was developed. For the energy sector, the capability of WEBAM to generate multi-material components was applied to create copper structures on steel base components with good adherence.