Name
Technical Session XIV - MSEC-155836
Date & Time
Thursday, June 26, 2025, 5:10 PM - 5:25 PM
Description
The hierarchical porous structures of copper (Cu) have gained significant attention for their wide range of applications in filtration, catalysis, and lightweight structural components. This is largely due to copper's unique combination of mechanical strength, durability, and permeability. The inherent properties of copper make it an ideal candidate for creating advanced materials that require both structural integrity and high surface areas. However, one of the key challenges that remains in materials engineering is achieving precise control over the pore size distribution within these structures. In this study, we present a novel approach that integrates the space-holder technique with binder jetting additive manufacturing, aimed at fabricating hierarchical porous Cu structures that feature both meso-scale and macro-scale pores with tailored architectures.
In the initial phase of our experiment, sodium chloride (NaCl) powder was employed as a removable space holder within the Cu powder matrix to create a meso-scale porous structure. By adjusting the volume percentage of NaCl within the green compact, we were able to modulate the porosity of the material. Higher NaCl content resulted in increased porosity, which was crucial for ensuring that the meso-scale pores could be accurately and reproducibly formed during the subsequent sintering process. This process not only allowed for controlled pore formation but also enabled us to fine-tune the mechanical properties of the resulting material.
In the second stage, the Cu-NaCl powder mixture was used in binder jetting 3D printing. The meso-scale pores were formed through the removal of the NaCl space holder after the sintering process, while the macro-scale channels were directly printed according to specific design specifications. Binder jetting enabled us to achieve precise control over the macro-scale architecture, which allowed for the fabrication of complex geometries that are not feasible with traditional manufacturing methods. This dual-scale porosity significantly enhanced the material's permeability and functionality, which is crucial for applications that require both high surface area and structural integrity.
To thoroughly characterize the hierarchical pore structure, we initially employed optical microscopy to observe pore morphology and measure the pore size on the meso-scale. Subsequently, X-ray micro-CT scanning was utilized to reconstruct the sample's 3D microstructure. This provided a detailed assessment of the pore size distribution and overall porosity. The combination of these imaging techniques enabled a comprehensive characterization of the porous structures, confirming that our fabrication approach successfully achieved well-distributed meso- and macro-scale pores with customizable porosity levels.
The results of our study demonstrate a versatile and scalable method for producing porous Cu structures with customizable porosity levels and pore size distributions. This method is tailored to cater to various industrial applications. Additionally, it holds the potential for optimization and application to other metal systems, highlighting its broad applicability in manufacturing advanced porous materials with multifunctional capabilities.
Location Name
Gardenia
Full Address
Hyatt Regency
220 N Main St
Greenville, SC 29601
United States
220 N Main St
Greenville, SC 29601
United States
Session Type
Technical Session
Paper #
MSEC-155836
Author List
Rui Dong, Karla Magdalena Becerra Rosas, Wenda Tan
Paper Title
[B] Fabrication of Hierarchical Porous Copper Structures Using Binder Jetting and Space-Holders
Session Chair
Yang Yang