Laser powder bed fusion of pure copper electrodes

This study explores the fabrication and characterization of a pure copper electrode for an EDM equipment using laser powder bed fusion (LPBF) and comparing its performance with an original cast sample. The microstructural, mechanical, electrical, thermal, and corrosion characteristics of the samples were analyzed. The microstructure of the additively manufactured (AM) sample exhibited superior mechanical properties, with an 18% increase in ultimate tensile strength and more than two times greater elongation in comparison with those of the cast sample. Moreover, the electrical and thermal conductivity coefficients of the AM sample were found to be consistent with industry standards as 5.52×107 S/m and 361 W/mK, respectively. Additionally, the potentiodynamic polarization corrosion test results of the AM sample further exhibited superior corrosion resistance in terms of the corrosion potential particularly in a 3.5% NaCl environment. Advanced electron microscopy techniques were used to investigate the differences in the properties of the AM and cast samples and further shed light on the superior properties of the LPBF counterpart. Despite challenges in manufacturing pure copper components through LPBF, this study demonstrates the feasibility of producing a functional part that competes effectively with cast counterparts and excels in certain aspects.