Manufacturing of high strength and high conductivity copper with laser powder bed fusion

Additive manufacturing (AM), known as 3D printing, enables rapid
fabrication of geometrically complex copper (Cu) components for electrical
conduction and heat management applications. However, pure Cu or Cu alloys
produced by 3D printing often suffer from either low strength or low
conductivity at room and elevated temperatures. Here, we demonstrate a
design strategy for 3D printing of high strength, high conductivity Cu by
uniformly dispersing a minor portion of lanthanum hexaboride (LaB6)
nanoparticles in pure Cu through laser powder bed fusion (L-PBF). We show
that trace additions of LaB6 to pure Cu result in an improved L-PBF
processability, an enhanced strength, and improved thermal stability, all
whilst maintaining a high conductivity.  The presented strategy
could expand the applicability of 3D-printed Cu components to more
demanding conditions where high strength, high conductivity, and thermal
stability are required.