The First Layer: Single-Track Insights into Direct Energy Deposition Processed Cu-Ni Thermoelectric Alloys
The shift to sustainable energy has accelerated the development of thermoelectric (TE) material for direct heat-to-electricity conversion without batteries or grid reliance. Cu-Ni alloys show promise for high-power, thermally stable TE applications like waste heat recovery and electronics cooling bu...
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MDPI AG
2025-05-01
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| Series: | Journal of Manufacturing and Materials Processing |
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| Online Access: | https://www.mdpi.com/2504-4494/9/6/170 |
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| author | Nick Williams Kyle Snyder Ian Smith Anthony Duong Everett Carpenter Radhika Barua |
| author_facet | Nick Williams Kyle Snyder Ian Smith Anthony Duong Everett Carpenter Radhika Barua |
| author_sort | Nick Williams |
| collection | DOAJ |
| description | The shift to sustainable energy has accelerated the development of thermoelectric (TE) material for direct heat-to-electricity conversion without batteries or grid reliance. Cu-Ni alloys show promise for high-power, thermally stable TE applications like waste heat recovery and electronics cooling but require thermal conductivity and microstructure optimization. This study investigates additive manufacturing (AM) of Cu-Ni alloys via laser powder-directed energy deposition (L-DED), enabling precise control over deposition parameters. Track geometries were analyzed using linear mass density (M<sub>L</sub>) and linear heat input (H<sub>L</sub>), which influence deposition quality and microstructural characteristics. A weighted qualitative process parameter decision matrix was developed to evaluate process conditions systematically. Optimal deposition was achieved with H<sub>L</sub> < 70 J/mm for M<sub>L</sub> ~0.016–0.021 g/mm and 98 J/mm < H<sub>L</sub> < 137 J/mm for M<sub>L</sub> = 0.026 g/mm, corresponding to an energy-to-mass ratio of ~4000 ± 500 kJ/g. While this study does not directly assess thermoelectric properties, it provides essential first-layer insights into how processing conditions affect track geometry, defect formation, and microstructure—information that is foundational for optimizing multi-layer builds and, ultimately, improving thermoelectric performance. These findings mark a critical step toward predictive process optimization and the accelerated design of Cu-Ni-based thermoelectric materials using AM techniques. |
| format | Article |
| id | doaj-art-6ccf30f477f7413197f7a66e3b2eafd1 |
| institution | DOAJ |
| issn | 2504-4494 |
| language | English |
| publishDate | 2025-05-01 |
| publisher | MDPI AG |
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| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj-art-6ccf30f477f7413197f7a66e3b2eafd12025-08-20T03:16:18ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942025-05-019617010.3390/jmmp9060170The First Layer: Single-Track Insights into Direct Energy Deposition Processed Cu-Ni Thermoelectric AlloysNick Williams0Kyle Snyder1Ian Smith2Anthony Duong3Everett Carpenter4Radhika Barua5Mechanical and Nuclear Engineering, Virginia Commonwealth University, Richmond, VA 23284, USACommonwealth Center for Advanced Manufacturing, Disputanta, VA 23842, USAMechanical and Nuclear Engineering, Virginia Commonwealth University, Richmond, VA 23284, USAMechanical and Nuclear Engineering, Virginia Commonwealth University, Richmond, VA 23284, USAMechanical and Nuclear Engineering, Virginia Commonwealth University, Richmond, VA 23284, USAMechanical and Nuclear Engineering, Virginia Commonwealth University, Richmond, VA 23284, USAThe shift to sustainable energy has accelerated the development of thermoelectric (TE) material for direct heat-to-electricity conversion without batteries or grid reliance. Cu-Ni alloys show promise for high-power, thermally stable TE applications like waste heat recovery and electronics cooling but require thermal conductivity and microstructure optimization. This study investigates additive manufacturing (AM) of Cu-Ni alloys via laser powder-directed energy deposition (L-DED), enabling precise control over deposition parameters. Track geometries were analyzed using linear mass density (M<sub>L</sub>) and linear heat input (H<sub>L</sub>), which influence deposition quality and microstructural characteristics. A weighted qualitative process parameter decision matrix was developed to evaluate process conditions systematically. Optimal deposition was achieved with H<sub>L</sub> < 70 J/mm for M<sub>L</sub> ~0.016–0.021 g/mm and 98 J/mm < H<sub>L</sub> < 137 J/mm for M<sub>L</sub> = 0.026 g/mm, corresponding to an energy-to-mass ratio of ~4000 ± 500 kJ/g. While this study does not directly assess thermoelectric properties, it provides essential first-layer insights into how processing conditions affect track geometry, defect formation, and microstructure—information that is foundational for optimizing multi-layer builds and, ultimately, improving thermoelectric performance. These findings mark a critical step toward predictive process optimization and the accelerated design of Cu-Ni-based thermoelectric materials using AM techniques.https://www.mdpi.com/2504-4494/9/6/170additive manufacturingthermoelectricdirect energy depositionlaser-additive manufacturingsustainable materials |
| spellingShingle | Nick Williams Kyle Snyder Ian Smith Anthony Duong Everett Carpenter Radhika Barua The First Layer: Single-Track Insights into Direct Energy Deposition Processed Cu-Ni Thermoelectric Alloys Journal of Manufacturing and Materials Processing additive manufacturing thermoelectric direct energy deposition laser-additive manufacturing sustainable materials |
| title | The First Layer: Single-Track Insights into Direct Energy Deposition Processed Cu-Ni Thermoelectric Alloys |
| title_full | The First Layer: Single-Track Insights into Direct Energy Deposition Processed Cu-Ni Thermoelectric Alloys |
| title_fullStr | The First Layer: Single-Track Insights into Direct Energy Deposition Processed Cu-Ni Thermoelectric Alloys |
| title_full_unstemmed | The First Layer: Single-Track Insights into Direct Energy Deposition Processed Cu-Ni Thermoelectric Alloys |
| title_short | The First Layer: Single-Track Insights into Direct Energy Deposition Processed Cu-Ni Thermoelectric Alloys |
| title_sort | first layer single track insights into direct energy deposition processed cu ni thermoelectric alloys |
| topic | additive manufacturing thermoelectric direct energy deposition laser-additive manufacturing sustainable materials |
| url | https://www.mdpi.com/2504-4494/9/6/170 |
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