Toward the process parameters optimization and characterization of CuCrZr alloy processed via the directed energy deposition method

Official URL: https://dx.doi.org/10.1007/s40964-026-01527-9

Additive manufacturing (AM) of copper-based alloys remains challenging due to their high laser reflectivity and thermal conductivity. To address these limitations and enable the production of defect-free components using laser powder directed energy deposition (LP-DED), process optimization beyond single tracks and thin samples is essential. The objective of this study is to fabricate high-quality bulk samples from CuCrZr alloy and establish a foundation for manufacturing functional components. First, a comprehensive investigation was conducted to optimize single-track deposition with respect to key geometrical characteristics, including wetting angle, track height, and width, using two different laser spot sizes. The influence of laser power, scan speed, powder feed rate, and laser spot size on track formation was systematically examined. The optimized parameters were then applied to fabricate bulk samples, with particular attention to challenges related to part’s height. In addition, the microstructural features of the bulk CuCrZr samples were analyzed. The results demonstrate that achieving defect-free bulk samples requires a relatively high laser power (820 W) and a low scan speed (420 mm/min) to ensure a stable melt pool and strong bonding between adjacent tracks. The resulting bulk part showed a relative density of 0.981 indicating high build quality compared to the previous studies. The findings is potentially provide valuable information toward the production of actual components from this alloy.