Copper and its alloys are considered key materials in aerospace engine construction due to their high thermal conductivity, electrical conductivity and corrosion resistance. However, their processing in metallic 3D printing, in particular by means of laser beam melting (LPBF), was technically limited for a long time. The strong reflection in the near infrared range, at around 1064 nm, led to instabilities in the melting process. The Chinese manufacturer Farsoon is now addressing this challenge with the further development of its LPBF platform FS621M-Cu.
Farsoon had already established the first processes for processing copper alloys on the smaller FS271M system in 2017. This was followed in 2023 by a collaboration with a leading aerospace company to develop a large-scale system for CuCrZr components. The FS621M-Cu has a construction volume of 620 × 620 × 1100 mm³ and is equipped with four 1000 watt ytterbium fiber lasers (1060-1080 nm). In combination with an optimized process window, reflection-reducing chamber coatings and active thermal control, this enables stable and reproducible printing processes of highly reflective materials.
A central field of application is the production of monolithic combustion chamber linings for liquid engines. These components must also be able to withstand high mechanical loads and integrate a sophisticated cooling system. Conventional production using turning, soldering and drilling is complex and cost-intensive. Additive construction allows complex cooling channels to be integrated directly and thermal efficiency to be improved.
In August 2023, the industrial partner successfully produced a lining with a diameter of 600 mm and a height of 850 mm. Tests confirmed almost theoretical density (8.86 g/cm³), high thermal conductivity (>345 W/m-K) and flawless microstructure. The dimensional accuracy of the internal geometries was also verified using X-ray analysis. The development thus shows that additively manufactured copper components in large format are increasingly suitable for industrial use.
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