Increase In Thermal Conductivity Research Articles

Effect of ten different physical parameters on solar still productivity: Theoretical modeling

AbstractSolar distillation using solar stills is widely recognized as a clean and cost‐effective method for producing freshwater. However, due to its straightforward design, solar still performance is greatly influenced by various physical characteristics. Many researches have evaluated solar still parameters, while only a few articles have concerned physical ones. Therefore, this article aims to investigate the effect of different physical parameters on solar still productivity through thermal modeling. The theoretical results were validated with those of a previous experimental model, showing a good agreement with each other. The results reveal that daily productivity experiences significant improvement with an increase in plate emissivity or insulation thickness. Conversely, an increase in water mass, glass absorptivity or insulation thermal conductivity leads to a substantial reduction in productivity. Notably, water transmissivity and plate absorptivity do not affect productivity. Modest enhancements in productivity can be achieved by reducing the effective emissivity between water and glass. While the initial temperature of water has a minor impact on productivity at low water mass, it exhibits a substantial improvement effect at high water mass. These results can be a good guidance for the designers and manufacturers to develop more efficient designs that maximize the production of clean water.

Prestrain Guided Yield of Large Single-Crystal Nickel Foils with High-Index Facets.

Single-crystal metal foils with high-index facets are currently being investigated owing to their potential application in the epitaxial growth of high-quality van der Waals (vdW) film materials, electrochemical catalysis, gas sensing and other fields. However, the controllable synthesis of large single-crystal metal foils with high-index facets remains a great challenge because high-index facets with high surface energy are not preferentially formed thermodynamically and kinetically. Herein, single-crystal nickel foils with a series of high-index facets are efficiently prepared by applying prestrain energy engineering technique, with the largest single-crystal foil exceeding 5×8 cm2 in size. In terms of thermodynamics, the internal mechanism of prestrain regulation on the formation of high-index facets is proposed. Molecular dynamics simulation is utilized to replicate and explain the phenomenon of multiple crystallographic orientations resulting from prestrain regulation. Additionally, large-sized and high-quality graphite films are successfully fabricated on single-crystal Ni(012) foils. Compared to the polycrystalline nickel, the graphite/single-crystal Ni(012) foil composites show more than five-fold increase in thermal conductivity, thereby showing great potential applications in thermal management. This study hence presents a novel approach for the preparation of single-crystal nickel foils with high-index facets, which is beneficial for the epitaxial growth of certain two-dimensional materials. This article is protected by copyright. All rights reserved.

Enhancing the Conductivity and Thermoelectric Performance of Semicrystalline Conducting Polymers through Controlled Tie Chain Incorporation.

Conjugated polymers are promising materials for thermoelectric applications, however, at present few effective and well-understood strategies exist to further advance their thermoelectric performance. Here a new model system is reported for a better understanding of the key factors governing their thermoelectric properties: aligned, ribbon-phase poly[2,5-bis(3-dodecylthiophen-2-yl)thieno[3,2-b]thiophene] (PBTTT) doped by ion-exchange doping. Using a range of microstructural and spectroscopic methods, the effect of controlled incorporation of tie-chains between the crystalline domains is studied through blending of high and low molecular weight chains. The tie chains provide efficient transport pathways between crystalline domains and lead to significantly enhanced electrical conductivity of 4810 S cm-1, which is not accompanied by a reduction in Seebeck coefficient or a large increase in thermal conductivity. Respectable power factors of 173 µW m-1 K-2 are demonstrated in this model system. The approach is generally applicable to a wide range of semicrystalline conjugated polymers and could provide an effective pathway for further enhancing their thermoelectric properties and overcome traditional trade-offs in optimization of thermoelectric performance.

Insight into the bidirectional dynamics of hyperbolic tangent hybrid nanomaterial subject to Nield’s conditions using numerical approach

A hyperbolic tangent fluid model characterized by shear rate dependent viscosity together with the effects of hybrid nanoparticles, Brownian motion, thermo-diffusion, and Nield’s conditions, is utilized for thermal enhancement purpose. Five percent copper nanoparticles and twenty percent alumina nanoparticles are submerged into ethylene glycol with the parametric influence of tangent hyperbolic fluid to obtain the tangent hyperbolic hybrid nano suspension. Numerical solutions of the nondimensionalized conservation laws are found by the Keller-box method. The influence of various parametric factors on velocity, temperature, concentration, Nusselt number, and Sherwood number has been discussed. A constant Nusselt number is noted with the influence of Nield’s constraints. A 90% increase in thermal conductivity is achieved by dispersing 5% copper and 20% alumina nanoparticles into the ethylene glycol with the influence of hyperbolic tangent fluid. The error and convergence analysis of the numerical solution have been discussed, along with the validation of the obtained numerical results.

Effect of Cu addition on the thermal conductivity and mechanical properties of Mg–Zn-xCu-Ce alloys

Thermal conductivity and mechanical properties of Mg–Zn-xCu-Ce alloys with different Cu contents under low extrusion temperature were systematically investigated in this work. The results shows that MgZnCu and Ce-rich (Mg, Zn, Cu, Ce) phase were formed in Mg–Zn-xCu-Ce alloys with high Cu content, which have significantly effect on the thermal conductivity and dynamic recrystallization (DRX). The distribution of grain morphology and LAGBs indicates that CDRX is the main mechanism. The addition of Cu element has an inhibitory effect on the DRX behavior, greatly refining the DRXed grains. After extrusion, a large amount of nano-phase is dispersed in the MZEC alloy, which has a strong pinning effect on dislocations. The formation of MgZnCu phase with high thermal conductivity sacrifices the solute atoms of Zn and Cu in α-Mg matrix, which leads to reduction of lattice distortion of Mg matrix, thereby ensuring high thermal conductivity of Mg–Zn–Cu–Ce ternary magnesium alloys. With the increase of Cu content, the strength and thermal conductivity of the alloy gradually increases. When the Cu content is 3.6 wt%, UTS (ultimate tensile strength), YS (yield strength), EL (elongation) and thermal conductivity are 350 MPa, 317 MPa,15.8% and 135 W/m∙K, respectively.

A unified hybrid micromechanical model for predicting the thermal and electrical conductivity of graphene reinforced porous and saturated cement composites

Graphene fillers have gained widespread attention as functional reinforcements for cement composites due to their excellent physical properties. The prediction of the thermal and electrical properties of graphene reinforced cement composites (GRCCs) is of great importance for developing intelligent and multifunctional civil engineering materials and structures. In this current work, a unified hybrid micromechanical model combining effective medium theory (EMT) and Mori-Tanaka-Benveniste (MTB) is developed to simultaneously predict the thermal and electrical conductivity of the GRCCs with considering pores and saturation, in which mechanisms including phonon transport, electron tunnelling and Maxwell-Wagner-Sillars (MWS) polarization are incorporated. Graphene nanoplatelets (GNPs) reinforced cement composites (GNPRCCs) samples are prepared and tested to validate the developed unified model. The results show that the electrical conductivity of the GNPRCCs is more sensitive to saturation than the thermal conductivity. When the porosity n = 0.2 and the GNP concentration is 1 wt%, the relative thermal and electrical conductivity increases by 5 % and 193 %, respectively, when the saturation index increases from 0.6 to 1. Elongated pores are more favorable for the formation of ionic networks for electrical conductivity in the saturated GNPRCCs, while spherical pores are more beneficial for heat transport. Elongated graphene fillers are preferred for enhancing both the thermal and electrical conductivity of dry and saturated GNPRCCs. The work is envisaged to provide guidelines for developing multifunctional cement composites.

Performance of foam concrete developed from construction and demolition waste

Unconscious industrialization, urbanization and consumption of natural resources pose a serious threat to the environment. The threat can be reduced by upcycling construction and demolition waste (CDW) in the production of foam concrete, which is a special type of concrete used especially for thermal insulation purposes. This study aims to use of CDW as a source of fine aggregate (0-4 mm) in the production of foam concrete mixtures. A series of mixtures with target density values between 500 and 900 kg/m3 were designed with various recycled aggregate and foam contents to investigate the physical, mechanical and thermal properties of the mixtures. Findings of the study reveal that mixtures with an elevated foam content possess a greater number of larger pores, which, as observed through microscopy, form interconnected structures that are porous. On the other hand, adding more fine recycled material (FRM) makes the matrix denser, which reduces the overall porosity and increases the packing density. In contrast to increased content of FRM, correlation coefficient of (-0.77) reveal a more powerful inverse relationship between risen level of foam content (-0.67) and the reduction ratio of fresh-to-dry density and the increase in compressive strength from 7 to 28 days. It is also known that mixes with more foam have better thermal insulation because they trap more air, while mixes with more FRM show an increase in thermal conductivity. The sensitivity analysis showed that changes in thermal conductivity are almost three times as sensitive for FRM content, which means they have a bigger effect than changes in foam content. Employing the Taguchi method, (R_0.714) emerges as the most efficient tested combination indicative of superior overall performance. Notably, the Taguchi method predicts the untested combination (0.100-F/C ratio + 0.714-R/C ratio) as potentially more efficient, suggesting avenues for further exploration and optimization. This study furnishes valuable insights into sustainable construction practices by reutilizing CDW in foam concrete production, thereby contributing to both environmental conservation and enhanced structural outcomes.

Microstructure and properties of Cu/Si composites for electronic packaging: Effect of tungsten layer on silicon particles

Cu/Si composite are ideal electronic packaging materials, but the intense formation of Cu-Si intermetallics during preparation leads to a significant decrease in their plasticity and thermal conductivity. In this paper, a W layer was formed on Si particles using the sol-gel method, and Cu/Si composites were prepared by hot pressing. The results show that the maximum thickness of the W layer is 1.64 μm, and the minimum thickness is only 809nm. The W layer acts as a diffusion barrier, effectively inhibiting the Cu-Si interfacial reaction and intermetallics formation, thus preventing the deterioration of matrix and reinforcement properties. Compared with the Cu/Si composite, the elongation of the Cu/Si@W composite improves from 0.2% to 1.7%, and the thermal conductivity increases by 7 times to 233.9W/(m·K). Additionally, among the four samples, the Cu/Si@W composite has the lowest coefficient of thermal expansion (CTE). The W layer enhances the mechanical properties and thermal conductivity while reducing the CTE of Cu/Si composite for improved electronic packaging application.

Enhancements in thermal properties of binary alkali chloride salt by Al2O3 nanoparticles for thermal energy storage

The cost-effective molten chloride salts are promising heat transfer fluids for next-generation concentrating solar plants. However, their limited specific heat capacities and thermal conductivities hinder their applications. In this paper, molten salt-based nanofluids based on a binary chloride (50 mol.% NaCl, 50 mol.% KCl) with Al2O3 nanoparticles were proposed to enhance the thermal properties. Firstly, molecular dynamics simulations were employed to investigate the thermal properties of these nanofluids, focusing on various nanoparticle volume fractions within 1100∼1600 K. The findings reveal that as the nanoparticle fraction increases from 0% to 7%, the specific heat capacity and dynamic viscosity improve by ≈14.9% and 34.8%∼38.6%, respectively. Concurrently, the thermal conductivity increases by 10.0%∼16.5%. Then, microstructure evolution was analyzed to elucidate the enhancing mechanism of the thermal conductivity. Specifically, the negatively charged nanoparticle surface selectively attracts Na+ and K+, resulting in the formation of a compressed layer around the nanoparticle where the short-range order of ions was intensified. As a result, the compressed layer serves as a thermal conduit between the Al2O3 nanoparticle and the surrounding salt, resulting in the enhancement of the thermal conductivity. Furthermore, additional analyses of thermal diffusion properties and energy density distributions provide indirect evidence for the existence of the compressed layer where ionic motion is restricted, further validating the enhancing mechanism.

Enhanced thermal conductivity and mechanical property via improvement of hydrogen bonding between hexagonal boron nitride and aramid copolymer

This study focuses on enhancing thermal properties of aramid copolymer nanocomposites by integrating hexagonal boron nitride (hBN). Pristine hBN (P-hBN) is first subjected to oxidative heat treatment at 900 °C, producing thermally treated hBN (T-hBN), which significantly improves thermal conductivity while also increasing the tensile properties of composites. The study further explores the effect of different diamine co-monomers, 3,4′- and 4,4′-oxydianiline (ODA), on the nanocomposite properties. Both types of ODA-based composite films show improvement in various properties containing T-hBN. With 20 wt% of T-hBN, the 3,4′-ODA and 4,4′-ODA-based films exhibit 33.2 % and 290 % increase in tensile strength and thermal conductivity, respectively. The functionalization of hBN by heat treatment enhances the interaction between aramid copolymer and hBN and prevents the aggregation of hBN. The rough interface was shown in fractured images for films with T-hBN, suggesting that the composite films with T-hBN withstand higher external forces. In addition, it was observed that T-hBN exhibits better dispersion compared to P-hBN. This is supported by molecular dynamics (MD) simulation, and, in addition, it also provides the underlying mechanism for the property differences between both types of co-monomers.

A novel candidate shape-stabilized phase change material for building energy conservation based on lauric acid/roasted iron tailings-expanded graphite

This study presents the fabrication of a novel shape-stabilized phase change material (SSPCM) characterized by high thermal capacity and heat transfer efficiency. The material was composed of lauric acid (LA) embedded in roasted iron tailings (RIT) and expanded graphite (EG), utilizing a straightforward, low-cost, and direct impregnation method. The as-prepared LA/RIT-EG SSPCM underwent a comprehensive analysis of leakage tests, surface morphology, chemical compatibility, phase change properties, thermal stability, and reliability. Furthermore, the heat transfer efficiency and thermal conductivity were measured through cooling tests and a laser thermal conductivity analyzer, respectively. The LA/RIT-EG formulation demonstrated an ability to absorb 61.57 wt% LA without leakage, maintaining excellent form-stability with a mass fraction proportion of 29:9.43 for RIT and EG. DSC results revealed phase temperatures and latent heats of 42.49–46.31 °C and 108.1–113.1 J/g, respectively. Compared to pure LA, LA/RIT-EG exhibited a 489.7 % increase in thermal conductivity. Additionally, heat storage and release rates were improved by 81.25 % and 88.24 %, respectively. The study elucidated the mechanism behind the enhancement in encapsulation capacity and thermal conductivity by RIT-EG, validated through specific surface area and wettability tests. Overall, the results suggest that LA/RIT-EG, characterized by high thermal capacity and heat transfer efficiency, holds promise as a potential candidate for thermal energy storage, particularly in the context of energy conservation in buildings.

On the Influence of Humidity on a Thermal Conductivity Sensor for the Detection of Hydrogen.

Thermal conductivity sensors face an omnipresent cross-influence through varying humidity levels in real-life applications. We present the results of investigations on the influence of humidity on a hydrogen thermal conductivity sensor and approaches for predicting the behavior of thermal conductivity towards humidity. A literature search and comparison of different mixing equations for binary gas mixtures were carried out. The theoretical results were compared with experimental results from three different thermal conductivity sensors with mixtures of water vapor in nitrogen. The mixing equations show a large discrepancy between each other. Some of the models predict a continuously decreasing thermal conductivity and some predict an increasing thermal conductivity for increasing levels of humidity. Our measurements indicate an increase in thermal conductivity followed by a decrease after reaching a peak value. It is shown that the measured behavior is reproducible with different sensors. Depending on the sensor, this corresponds to an error up to 2 vol.% in the measured hydrogen value. The measured behavior is consistent with only one of the three models. Compared to this model, our own sensor shows a maximum deviation of 1.4%. Mixing equations for gas mixtures must be chosen carefully, taking into consideration whether mixing partners include polar or non-polar molecules. Some simplified mixing equations cannot be used to calculate the thermal conductivity of water vapor in air or nitrogen.

Thermal protection properties of profiled timber with peat-vermiculite insulation

Today, the use of environmentally friendly materials is becoming increasingly important. The construction of energy-saving buildings with enclosing structures made of insulated profiled timber, is one of the most promising areas in low-rise construction.Materials having minimum negative impact on the environment during their operation, include new construction insulation materials based on peat-vermiculite granules. The paper studies the main physical properties of wooden exterior walls made of profiled timber, in which peat vermiculite is used as insulation, thermal conductivity of which ranges from 0.05 to 0.06 W/(m·K). For this purpose, numerical simulation is performed for the heat-mass transfer in wooden enclosing structures made of insulated timber with three different connector options.The temperature and heat flow distributions are obtained as a result of modeling stationary thermal conductivity processes in timber structures. It is shown that plywood connectors do not affect the thickness temperature distribution in wooden walls with peat-vermiculite insulation. An increase in thermal conductivity of insulation has no significant effect on the temperature difference along the connector axis or outside the region of its temperature influence.It is found that the thickness of the peat-vermiculite insulation layer should be at least 0.176 m to ensure the compliance with the main requirements for thermal protection properties of enclosing structures in the climatic conditions of Tomsk. The greatest heat loss with a minimum insulation thickness is observed for the wall made of profiled insulated timber with T-shaped connectors. A high-strength timber with the additional central lamella has the best thermal protection with the lowest insulation thickness.

Nanocarbon‐Based Hybrid Fillers in Thermally Conductive Polymer Composites: A Review

With the broad commercialization of microelectronics, 5G communication, and new energy vehicles, the demand for polymer composites with high thermal conductivity (TC) increases. Carbon‐based nanomaterials have high TC, are of lightweight and low cost, and have been widely studied as thermally conductive fillers for composites. In this article, carbon‐based thermal conductive fillers in polymer composites are focused on. It summarizes the treatments of functionalization, directional arrangement, and dispersion of carbon‐based nanofillers. Moreover, from the perspective of nanocarbon, hybrid nanofillers are divided into three categories: carbon/carbon, carbon/ceramics, and carbon/metal for the first time, and the thermal conductive effect of these hybrid fillers is discussed. Finally, potential areas for future research and development of thermal interface materials are discussed.

Growth mechanism of bismuth-filled nanoporous silicon with improved structural stability and low thermal conductivity

Nano porous silicon (PS) is a strong candidate for thermoelectric application, but it shows low structural stability and is prone to collapse. To enhance the structural stability of PS and offer a new way to improve its electrical conductivity, PS was prepared by electrochemical etching and Bi nanowires were fabricated in the pores of PS by electrodeposition. In addition, for studying the effect of structures on the properties of Bi-filled PS composites, aperiodic single-layer (SL) structure, and periodic rugate (Rgt) structure and Bragg structure PS samples were prepared by changing the etching current waveform and etching time. The results show that the initial Bi deposition position and filling fraction of Bi nanowires in PS templates can be precisely controlled. Since Bi nanowires have significantly different continuity in Rgt and Bragg structures compared with SL structures, we proposed two growth mechanisms of Bi nanowires, including the axis-growth mechanism and transverse-axis-growth mechanism, with the supports of the experimental results of XRD, SEM, and EDS.The room temperature thermal conductivities of pristine and Bi-filled PS layers are in the ranges of 4.5 ∼ 5.0 and 4.2 ∼ 6.0 W･m−1K−1, respectively, about 1/10 of the original unetched silicon wafer. No apparent increase of thermal conductivity was observed in any Bi-filled composites. In addition, the thermal conductivities of PS layers with Bragg structure, including pristine and Bi-filled PS composites, are significantly lower than those of the other two structures.SEM images also demonstrates that Bi greatly improved the mechanical property of PS composites, especially the periodic structures composites. This study firmly demonstrates that Bi-filling in PS with periodic Bragg structure is practical to obtain nanocomposites with low thermal conductivity and improved structural stability. It offers a new dimension to optimize the property of PS for thermoelectric application by pore configuration design and controllable nanowire Bi filling.

The Role of Reduced Graphene Oxide in Enhancing the Mechanical and Thermal Properties of a Rubber Cover Joint.

The development of high-performance rubber composites has always been a research hotspot in the field of conveyor belt manufacturing. In this work, a rubber cover joint composite made of reduced graphene oxide (rGO) was prepared using latex mixing and mechanical blending methods, with a steel wire rope conveyor belt as the research object, and the influence of the rGO content on the properties of the rubber composite is discussed. The structure and morphology characterization of the rGO/NR rubber show that the addition of rGO does not change its crystal structure, and 1.2 phr rGO is uniformly dispersed throughout the rubber composite. As more rGO is added, the mechanical properties of the rGO rubber cover joint first improve and then worsen. With the addition of 1.2 phr, the cross-linking density increases by 80.6%, the tensile strength of the rubber composites increases by 49.7%, the elongation at break increases by 23.6%, and the adhesion strength increases by 12.4%. The tensile strength of the rGO rubber cover joint can still maintain 72.5% of its pre-thermal aging value. The wear resistance and thermal conductivity increase as more phr is added. When 3.0 phr is added, the wear resistance of the rubber composites increases by 32.9%, the thermal conductivity increases by 118.8%, and the temperature difference at the completion of vulcanization decreases from 4.5 °C to 1.8 °C. The results show that when 1.2 phr of rGO is added, the rubber conveyor belt joint obtains the best comprehensive performance. These enhanced comprehensive properties allow for the practical application of rGO nanomaterials to conveyor belt rubber.

Influence of variable viscosity and slip on heat and mass transfer of immiscible fluids in a vertical channel

This study examines the heat and mass transfer phenomena that take place in a vertical channel containing immiscible fluids, specifically micropolar and viscous fluids. The main objective is to explore the impact of variable viscosity, velocity slip, and other pertinent parameters on various properties, including velocity, angular velocity, temperature, and diffusion. This investigation reveals a significant correlation between these parameters and the observed effects. Also analyzes the transfer rates of heat, mass, and velocity on both boundaries of the channel. This comprehensive examination provides valuable insights into the intricate mechanisms governing these transfer processes. To solve the complex system of coupled equations, the Runge-Kutta sixth-order method, utilizing the ND Solve Mathematica software is used. This numerical technique offers accurate and reliable solutions for simulating the dynamics of heat and mass transfer in this system. As a result, the velocity slip parameter and thermal conductivity increases, the velocity,angular velocity and temperature decreases within the system, reverse effect is observed in diffusion. These findings further enhance our understanding of the complex behavior of the immiscible fluids in the vertical channel are depicted graphically.

Solid Foam Insertion to Increase PCM-Based Thermal Energy Storage System Efficiency: Experimental Test and Numerical Simulation of Spherical Macrocapsules

Phase change materials (PCMs) are an interesting solution to increase the efficiency of thermal energy storage (TES) systems. The present work explores, with an experimental and computational study, the behavior of a paraffin wax encapsulated in a spherical containment system during the melting and solidification phases. The experimental tests were conducted by immersing the spherical capsule in a thermostatic water bath at different temperatures and measuring the temperatures at four different points inside the capsule. A two-dimensional CFD model of the sphere was then applied to investigate the effect of the insertion of a solid foam into the sphere to increase the system’s responsiveness under demanding conditions. In addition, an analysis of the solidification process considering two different wall materials (HDPE and aluminum) with different thermal conductivity was performed. The results suggest that embedded foams can represent a useful tool to increase the efficiency of a PCM-based TES, but, at the same time, they also highlight that a considerable increase in thermal conductivity is required to achieve significant advantages with respect to pure PCM systems.

In-situ crosslinking reaction of graphene oxide & waterborne epoxy resin to construct continuous phase anticorrosive coating

The mechanism of using graphene oxide as a two-dimensional filler to increase the path length of the corrosive medium to the metal surface is limited to improving the corrosion resistance of the coating. This study propose novel dispersion and in-situ crosslinking reaction mechanism for constructing water-based heavy-duty anticorrosive coatings by using graphene oxide (GO) and waterborne epoxy resin (WEP). The results showed that GO can be uniformly dispersed directly into WEP without complex functional modifications. Oxygen-containing functional groups on moleculars structure of GO&WEP co-polymerized with diethylenetriamine (DETA) forming a continuous phase film which improved the density of the coating. Characterization techniques such as Fourier-transform infrared spectroscopy (FTIR), X-ray diffraction (XRD), scanning electron microscopy (SEM), thermal conductivity measurement instrument, pencil hardness tester, adhesion tester, salt spray corrosion test chamber, and electrochemical impedance spectroscopy (EIS) were used to evaluate coating structure and performance properties. The results showed that graphene characteristics enhanced physical properties and anti-corrosion performance of composite coatings. The construction mechanism of the coating is different from that of the current GO modified and dispersed in the coating as a two-dimensional filler to extend the path length of the corrosive medium to the metal surface. The coatings prepared by adding the optimum mass ratio of 0.1–0.2 % GO to WEP have the best physical properties and anti-corrosion properties. When the GO content is 0.2 wt%, the thermal conductivity increases by 86.0 %. After added 0.025 wt% GO, the coating hardness is increased by two grades directly from 2B to HB. With the addition of GO concentration increased to 0.05 wt%, the adhesion is increased from 2 to level 1.When the GO content exceeds 0.05 %, the coating will not bulge off after 4 months of salt water immersion experiment.

Laser additive manufacturing of TiB2-modified Cu15Ni8Sn/GH3230 heterogeneous materials: Processability, interfacial microstructure and mechanical performance

Cu/Ni heterogeneous materials integrate excellent thermal conductivity and high-temperature mechanical properties, enabling them to be widely used in the aerospace domain. Differences in the thermal and physical properties of the Cu and Ni materials, however, make them difficult to be processed using the laser powder bed fusion (LPBF) additive manufacturing process. This study systematically examines the effects of various LPBF process parameters on microstructure, element diffusion, bonding strength and microhardness at the Cu/Ni interface, as well as investigating the mechanisms of defect formation within Cu/Ni heterogeneous materials. The results indicate that a reasonable control of laser energy input (<100 J/mm3) facilitates the Cu/Ni components through strong interfacial metallurgical bonding without pore defect formation. Compared to single-material Cu alloy, the ultimate tensile strength (UTS) of the horizontally bonded Cu/Ni specimen increased by 55.25 %, without significant reductions in elongation. The vertically bonded Cu/Ni tensile specimen fractured in the middle of the Cu region rather than the interfacial region, indicating superb interfacial bonding strength. Another advantage lies in the enhancement of thermophysical properties, with a 109.5 % increase in thermal conductivity achieved in the LPBF-fabricated Cu/Ni heterogeneous materials compared to the single-material Ni alloy. Quasi-static compression experiments indicated that the Cu/Ni lattice structure could absorb more energy when compressed parallel to the build direction (BD), compared to being perpendicular to the BD. This study provides guidance for the design and manufacture of high-performance Cu/Ni heterogeneous components via LPBF.