3D Printing Combined with Dealloying for Fabrication of Ultrafine Grain Nanoporous Cu

Abstract

Using a combination of selective laser melting (SLM) and de-alloying methods, we prepared ultrafine crystalline nanoporous Cu. The resulting porous Cu exhibits grains ranging from 30–90 nm in size, pore sizes ranging from 50–300 nm, and a ligamentous structure with melt pool morphology. It is believed that the formation of ultrafine grains with nanoporous microstructures occurs due to the fast cooling rate of the melt pool, repeated heating during the printing process, and the intrinsic immiscibility of Cu and Fe. Our focus in this study lies on investigating the combined effects of parameters such as laser power, scanning speed, and scanning spacing on porous Cu precursors and porous Cu pore structures in the SLM technique, utilizing Taguchi’s experimental method. The goal is to propose a design strategy for the rapid and high-precision fabrication of bulk ultrafine crystalline nanoporous metals. These metals hold promise for various functional applications and can be utilized in the preparation of porous metals across different systems.

Keywords

selective laser melting / dealloying / Cu-Fe alloy / nanoporous metals

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