Laser powder bed fusion of a Cu-Ni-Al alloy using the compositional grading approach

Using a modified laser powder bed fusion (LPBF) technique, a compositionally graded Cu-Ni alloy was fabricated. Through microstructural and mechanical characterization on the samples extracted from it, the addition of 7.6 wt.% Ni to Cu is identified as the minimum required for obtaining a crack-free and nearly-fully-dense coupons using LPBF. Subsequently, 3 wt.% Al was added to the Cu-7.6 wt.% alloy to deplete the solute Ni atoms from the matrix through the precipitation of Ni3Al upon aging of the LPBF Cu-Ni-Al alloy, which simultaneously enhances the strength and electrical conductance of the alloy. Through this example, we demonstrate the potential of high?throughput screening of alloys suitable for LPBF through the fabrication of the compositionally graded alloys and subsequent alloy design for optimum property combinations.