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Additive manufacturing (AM) as a disruptive technique has offered great potential to design and fabricate many metallic components for aerospace, medical, nuclear, and energy applications where parts have complex geometry. However, a limited number of materials suitable for the AM process is one of the shortcomings of this technique, in particular laser AM of copper (Cu) is challenging due to its high thermal conductivity and optical reflectivity, which requires higher heat input to melt powders. Fabrication of composites using AM is also very challenging and not easily achievable using the current powder bed technologies. Here, the feasibility to fabricate pure copper and copper-carbon nanotube (Cu-CNT) composites was investigated using laser powder bed fusion additive manufacturing (LPBF-AM), and 10 × 10 × 10 mm3 cubes of Cu and Cu-CNTs were made by applying a Design of Experiment (DoE) varying three parameters: laser power, laser speed, and hatch spacing at three levels. For both Cu and Cu-CNT samples, relative density above 90% and 80% were achieved, respectively. Density measurement was carried out three times for each sample, and the error was found to be less than 0.1%. Roughness measurement was performed on a 5 mm length of the sample to obtain statistically significant results. As-built Cu showed average surface roughness (Ra) below 20 µm; however, the surface of AM Cu-CNT samples showed roughness values as large as 1 mm. Due to its porous structure, the as-built Cu showed thermal conductivity of ~108 W/m·K and electrical conductivity of ~20% IACS (International Annealed Copper Standard) at room temperature, ~70% and ~80% lower than those of conventionally fabricated bulk Cu. Thermal conductivity and electrical conductivity were ~85 W/m·K and ~10% IACS for as-built Cu-CNT composites at room temperature. As-built Cu-CNTs showed higher thermal conductivity as compared to as-built Cu at a temperature range from 373 K to 873 K. Because of their large surface area, light weight, and large energy absorbing behavior, porous Cu and Cu-CNT materials can be used in electrodes, catalysts and their carriers, capacitors, heat exchangers, and heat and impact absorption.
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Laser-induced atmospheric Cu x O formation on copper surface with enhanced electrochemical performance for non-enzymatic glucose sensing
Copper oxide nanostructures are widely used for various applications due to their unique optical and electrical properties. In this work, we demonstrate an atmospheric laser-induced oxidation technique for the fabrication of highly electrochemically active copper oxide hierarchical micro/nano structures on copper surfaces to achieve highly sensitive non-enzymatic glucose sensing performance. The effect of laser processing power on the composition, crystallinity, microstructure, wettability, and color of the laser-induced oxide on copper (LIO-Cu) surface was systematically studied using scanning electron microscopy (SEM), grazing incidence X-ray diffraction (GI-XRD), Raman spectroscopy, energy dispersive X-ray spectroscopy (EDX), EDX-mapping, water contact angle measurements, and optical microscopy. Results of these investigations showed a remarkable increase in copper oxide composition by increasing the laser processing power. The pore size distribution and surface area of the pristine and LIO-Cu sample estimated by N 2 adsorption–desorption data showed a developed mesoporous LIO-Cu structure. The size of the generated nano-oxides, crystallinity, and electroactivity of the LIO-Cu were observed to be adjustable by the laser processing power. The electrocatalytic activity of LIO-Cu surfaces was studied by means of cyclic voltammetry (CV) within a potential window of −0.8 to +0.8 V and chronoamperometry in an applied optimized potential of +0.6 V, in 0.1 M NaOH solution and phosphate buffer solution (PBS), respectively. LIO-Cu surfaces with optimized laser processing powers exhibited a sensitivity of 6950 μA mM −1 cm −2 within a wide linear range from 0.01 to 5 mM, with exceptional specificity and response time (<3 seconds). The sensors also showed excellent response stability over a course of 50 days that was originated from the binder-free robust electroactive film fabricated directly onto the copper surface. The demonstrated one-step LIO processing onto commercial metal films, can potentially be applied for tuneable and scalable roll-to-roll fabrication of a wide range of high surface area metal oxide micro/nano structures for non-enzymatic biosensing and electrochemical applications.
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- Award ID(s):
- 1809520
- PAR ID:
- 10341591
- Date Published:
- Journal Name:
- Journal of Materials Chemistry C
- Volume:
- 9
- Issue:
- 42
- ISSN:
- 2050-7526
- Page Range / eLocation ID:
- 14997 to 15010
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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- Free Publicly Accessible Full Text
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Accepted Manuscript1.0
- Journal Article:
- https://doi.org/10.1039/d1tc01289d
