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Investigating production routes and application of nanotechnology for improved properties of porous copper structures

Ayub, Hassan (2025) Investigating production routes and application of nanotechnology for improved properties of porous copper structures. Master of Engineering thesis, Dublin City University.

Abstract
This master thesis presents the investigations conducted into advanced production routes for the fabrication of porous copper structures using different powder types. Porous copper structures are beneficial for several applications, such as heat sinks, air filtration, and catalysts. The study started with the use of two different types of powder particles (spherical and dendritic) for the production of porous copper structures using hydraulic pressing. The processing conditions examined in this study include powder type, compaction pressures, and concentrations of a pore-forming agent (polyvinyl alcohol or PVA). After compaction, the samples underwent a two-stage sintering process at specific temperatures. The study examined the morphology, porosity, and mechanical properties of the sintered samples. The analysis revealed that samples with a higher weight percentage of PVA demonstrated better consolidation and overlapping of copper powder particles, resulting in improved morphology. The highest porosity was achieved when the dendritic copper powder was mixed with the highest weight percentage of PVA. The hardness of the samples varied significantly due to their high porosity. Where the samples were prepared using spherical powders at high pressure, the highest hardness was observed. The study concluded that porous copper structures with porosity ranging from 14% to 26% can be effectively produced by controlling the compaction pressure and PVA concentration. Furthermore, this master's thesis examined the application of nanotechnology to enhance the optical absorption and conductivity of copper during the laser sintering process. Copper powders were mixed with different concentrations of carbon nanotubes (CNTs) and the optical properties of mixed powders were evaluated using spectroscopy. The Box-Behnken Design of Experiments methodology was used to optimize the infrared laser processing conditions for sintering. Spectroscopic analysis was conducted to evaluate the reflection and thermal absorption of the IR wavelengths by the Cu-CNT composites. Density and hardness measurements were taken for the laser-sintered Cu-CNT pellets. The coating of copper powders with CNTs demonstrated enhanced optical absorption, resulting in reduced reflection. Due to the enhanced optical absorption, increased control and sensitivity of the laser sintering process were achieved, which enabled improvement in the mechanical properties of strength, hardness, and density, while also enabling control over the composite thermal expansion coefficient. A maximum average hardness of 66.5 HV was achieved. Indentation test results of the samples revealed maximum tangential and radial stresses of 0.148 MPa and 0.058 MPa, respectively. Overall, the thesis provides detailed insights into the production of porous copper structures and the potential benefits of incorporating CNTs for enhancing optical and material properties.
Metadata
Item Type:Thesis (Master of Engineering)
Date of Award:18 March 2025
Refereed:No
Supervisor(s):Brabazon, Dermot
Subjects:Engineering > Materials
Engineering > Mechanical engineering
Engineering > Production engineering
Physical Sciences > Lasers
DCU Faculties and Centres:UNSPECIFIED
Use License:This item is licensed under a Creative Commons Attribution-NonCommercial-No Derivative Works 4.0 License. View License
Funders:Research Ireland
ID Code:31111
Deposited On:24 Nov 2025 11:24 by Dermot Brabazon . Last Modified 24 Nov 2025 11:24
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