Development of a novel processing route for dispersoid/precipitation-strengthened high conductive copper alloys by using metallized nano ceramics in additive manufacturing

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Due to their excellent thermal and electronic conductivity, Cu alloys play a fundamental role, e.g., in industrial applications or electro mobility. In laser-based additive manufacturing, the employment of low-alloy Cu alloys is limited by its high reflectivity and heat conductivity. Objective of the proposed research is the development of novel high-strength, high-conductive Cu alloys, tailor-made for selective laser melting (SLM) processes (using red and green laser light). Strengthening phases are introduced by means of mixing metallized ceramic nano-particles with a precipitation strengthened CuCrZr alloy. By using of a recursive alloys design strategy taking computational thermodynamics (CALPHAD) into account, powders will be produced by gas atomization and thoroughly characterized by electron microscopy methods (SEM, TEM, EDX, EBSD, FIB, APT). At the same time, a metallization process is applied to ceramic nano-particles to establish a homogeneous mixing during the subsequent laser melting process of the resulting MMCs. Accompanied by a process simulation, small test samples will be produced by means of SLM with systematically varying the process parameters and build strategies. According to the respective microstructure and mechanical/oxidation properties the alloy design will be adapted accordingly, to finally achieve an optimum combination between functional and structural material properties.