3D micro-extrusion of dense Cu-alloys and SiC structures

3D printing is gaining momentum in all areas of materials research due to the ability to create three-dimensional parts directly from CAD designs through adding materials layer by layer, producing near-net-shape complex geometries that would not be possible with subtractive manufacturing. Other benefits of 3D printing include mass customization, waste minimization, as well as fast prototyping. The use of 3D printing to fabricate heat transfer devices like heat exchangers and heat sinks has strong potential, especially to fabricate customized and complex freeform parts with improved flow and heat transfer, reduced weight and size and avoiding assembly operations. Copper and silicon carbide are materials with unique properties for use in high-performance HEXs. However, these materials are very difficult to process by (light-based) 3D printing technologies. An emerging technology that is unique in its ability to process a wide range of materials including Cu and SiC is 3D micro-extrusion. In this technology, parts are shaped by micro-extrusion of a powder loaded paste in a layer-wise manner and afterwards thermally post-processed to remove the binder and consolidate the green part into a dense component. The aim of this PhD is to develop complete processing routes for 3D micro-extrusion of dense copper and silicon carbide parts containing complex geometrical features relevant to heat transfer devices. The relationship between the characteristics of the 3D printing feedstock, processing conditions (printing & consolidation by heat treatment), microstructure and part properties and final performance of the heat transfer device will be elucidated in this PhD.