Effect of Laser Powder Bed Fusion Process Parameters on the Microstructures, Mechanical Properties, and Conductivity of CuCrZr Alloy

This study presented the preparation of high-density CuCrZr alloy samples using laser powder bed fusion (LPBF) and conducted characterization and testing of the surface morphology, porosity, microstructure, hardness, electrochemical corrosion resistance, and conductivity. The findings indicated that the formation of pores in the CuCrZr alloy may result from incomplete powder melting, significant powder splashing during the LPBF process, or copper element evaporation. By optimizing the process parameters to a laser power of 400 W, a scanning speed of 800 mm/s, a scanning spacing of 0.09 mm, and a layer thickness of 0.03 mm, samples with fewer pores were obtained. The influence of LPBF process parameters on the hardness value of alloys was mainly reflected in the influence of pores on the hardness value, with the highest average value of 84.91 +/- 5.32 HV0.2 and the lowest average value of 79.39 +/- 4.63 HV0.2. The lowest corrosion current density of the alloy was 2.330 x 10-5 A/cm2, and the polarization curves under different process parameters showed a clear passivation plateau, indicating that the corrosion products of the alloy may have sufficient protective effects on the interior of the alloy. The conductivity of the alloy was around 20% IACS, with the highest mean being 20.2% IACS and the lowest mean being 18.1% IACS. It indicated that the process parameters had no significant impact on the alloy properties.