Investigation of Wire-Arc Directed Energy Deposition of Copper for use in e-Mobility applications.

Additive manufacturing of pure copper is interesting for utilising high electrical and thermal conductivity properties for electrical as well as thermal applications. Wire-arc directed energy deposition is beneficial for producing large parts with less material wastage and is suitable for relatively less abundant resources like copper. The present study explores the feasibility and properties of parts produced using CuSn1 feedstock alloy and this process. Metallographic analysis and micro-hardness tests were conducted. The relative density of 99.99% is achieved, the micro-hardness is 64 HV0.1 and the grain sizes are observed to be growing along the build direction.