Open-cellular copper structures fabricated by additive manufacturing using electron beam melting

Cu reticulated mesh and stochastic open cellular foams were fabricated by additive manufacturing using electron beam melting. Fabricated densities ranged from 0.73 g/cm(3) to 6.67 g/cm3. The precursor Cu powder contained Cu(2)O precipitates and the fabricated components contained arrays of Cu(2)O precipitates and interconnected dislocation microstructures having average spacings of similar to 2 mu m, which provide hardness values similar to 75% above commercial Cu products. Plots of stiffness (Young's modulus) versus density and relative stiffness versus relative density were in very close agreement with the Gibson-Ashby model for open cellular foams. These open cellular structure components exhibit considerable potential for novel, complex, multi-functional electrical and thermal management systems, especially complex, monolithic heat exchange devices. (C) 2011 Elsevier B.V. All rights reserved.