Optimization of Process Parameters for CuCrZr Alloy Manufactured by Electron Beam Powder Bed Fusion Technology

The CuCrZr alloys exhibit advantageous mechanical properties and high electrical conductivity which make them promising for many applications in the electrical and aerospace engineering industries, e.g. in the manufacture of vacuum electronics and fusion energy research. Unfortunately, these two advantageous properties are in opposition to each other, i.e., the increase of hardness, is associated to a decrease of electrical conductivity. Additive manufacturing technologies are good candidates to balance these two aspects to achieve high performance parts. Powder-Bed-Fusion (PBF) techniques, in fact, involve rapid heating and cooling rates which allow to obtain huge microstructural refinements, thereby improving the mechanical properties without any significant loss in electrical conductivity. This study concerns the process parameter optimization for CuCrZr alloys produced using Electron-Beam-PBF technology using a trial-and-error approach. Material was characterized by porosity analysis, tensile and electrical conductivity measurements. The effect of process parameters on microstructure and densification behavior was also investigated.