About this Abstract |
| Meeting |
2026 TMS Annual Meeting & Exhibition
|
| Symposium
|
Additive Manufacturing and Innovative Feedstock Processing for Multifunctional Materials
|
| Presentation Title |
Laser Powder Bed Process Window for Copper |
| Author(s) |
Vi Nguyen, Leila Ladani, Jafar Razmi |
| On-Site Speaker (Planned) |
Vi Nguyen |
| Abstract Scope |
Lack-of-fusion (LOF) is a prevalent defect in laser powder bed fusion (LPBF) of copper, driven by the material’s high thermal conductivity and low absorptivity. This study introduces a fast, first-principles model based on Rosenthal’s analytical solution for a moving point heat source to predict melt pool geometry and construct LOF-based process windows. By applying geometric criteria—requiring the melt pool width to exceed hatch spacing and the depth to exceed layer thickness—the model identifies parameter sets likely to result in incomplete fusion. Simulations were conducted across a range of laser powers and scan speeds for both near-infrared (1064 nm) and green (515 nm) lasers, using material-specific absorptivity values. The resulting process maps were validated against literature-reported density data, showing strong agreement in identifying viable and defect-prone regimes. This framework enables rapid screening of LPBF parameters for copper and can be extended to other conductive metals, offering a lightweight alternative to computationally expensive simulations. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Additive Manufacturing, Copper / Nickel / Cobalt, Process Technology |