Improving laser powder bed fusion processability of pure Cu through powder functionalization with Ag

The Laser Powder Bed Fusion (LPBF) manufacturing of dense Cu parts with near infrared conventional systems is still challenging due to the high reflectivity and thermal conductivity of the powder. In this paper, we investigate a novel approach to improve LPBF processability of Cu through the modification of particle surface properties. Pure Cu powders were coated with a thin layer of high-conductivity Ag by electrodeposition. The coated powder was also heat-treated at 500 °C and 600 °C to promote diffusion at the coating interface, producing different powder particle configurations. LPBF equipped with 200 W laser was used to produce bulk samples using pure Cu and Cu/Ag powder, which were comprehensively characterized by electron microscopy and X-ray diffraction. The Ag coating improved the material processability and density, forming a eutectic phase mixture able to heal pores and defects at the end of the solidification process.