Current trends in electron beam and laser powder bed fusion additive manufacturing of copper alloys: Composition, defects, properties, and challenges
Currently, laser and electron beam powder bed fusion (L/E-PBF) are prevalent in metal additive manufacturing (AM), demonstrating exceptional potential for producing copper (Cu) alloy components indispensable for numerous aerospace, automotive, energy, and marine applications. However, despite ground...
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Elsevier
2025-05-01
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| Series: | Materials & Design |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S0264127525001625 |
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| author | Bhaskaranand Bhatt Alessandra Martucci Sara Biamino Daniele Ugues Federica Bondioli Laura Montanaro Mariangela Lombardi Paolo Fino |
| author_facet | Bhaskaranand Bhatt Alessandra Martucci Sara Biamino Daniele Ugues Federica Bondioli Laura Montanaro Mariangela Lombardi Paolo Fino |
| author_sort | Bhaskaranand Bhatt |
| collection | DOAJ |
| description | Currently, laser and electron beam powder bed fusion (L/E-PBF) are prevalent in metal additive manufacturing (AM), demonstrating exceptional potential for producing copper (Cu) alloy components indispensable for numerous aerospace, automotive, energy, and marine applications. However, despite groundbreaking advances in metal AM, Cu alloys remain underdeveloped. This comprehensive review highlights the unremitting efforts to develop superior and bespoke L/E-PBF Cu alloy parts. Initially, roadblocks to Cu alloy printability are identified, along with solutions to surmount them, followed by feedstock development in the context of L/E-PBF. An extensive process-induced defect analysis is presented to assess the impact of powder feedstock characteristics, process parameters, and heat treatments. Furthermore, the mechanical, electrical, corrosion, and tribological properties of L/E-PBF-fabricated Cu alloy parts are elaborated to elucidate the nexus among material-microstructure-performance. In addition, this review delves into various strengthening mechanisms, the significance of post-processing heat treatment in stabilising non-equilibrium microstructures, and its influence on the material-property space. The discussion then extends to the importance of modelling for comprehending complex melt pool dynamics. Finally, the review uncovers lacunas and presents critical future research aspects to boost the technological readiness of L/E-PBF Cu alloys/composites for accelerated adoption. |
| format | Article |
| id | doaj-art-c2fc1bda3eeb4ae8a8c8a54ea609e986 |
| institution | OA Journals |
| issn | 0264-1275 |
| language | English |
| publishDate | 2025-05-01 |
| publisher | Elsevier |
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| series | Materials & Design |
| spelling | doaj-art-c2fc1bda3eeb4ae8a8c8a54ea609e9862025-08-20T02:17:33ZengElsevierMaterials & Design0264-12752025-05-0125311374210.1016/j.matdes.2025.113742Current trends in electron beam and laser powder bed fusion additive manufacturing of copper alloys: Composition, defects, properties, and challengesBhaskaranand Bhatt0Alessandra Martucci1Sara Biamino2Daniele Ugues3Federica Bondioli4Laura Montanaro5Mariangela Lombardi6Paolo Fino7Department of Applied Science and Technology (DISAT), Politecnico Di Torino, Corso Duca degli Abruzzi 24, Torino 10129, Italy; Corresponding authors at: Department of Applied Science and Technology (DISAT), Politecnico Di Torino, Corso Duca degli Abruzzi 24, Torino 10129, Italy (M. Lombardi).Department of Applied Science and Technology (DISAT), Politecnico Di Torino, Corso Duca degli Abruzzi 24, Torino 10129, ItalyDepartment of Applied Science and Technology (DISAT), Politecnico Di Torino, Corso Duca degli Abruzzi 24, Torino 10129, Italy; Center of Integrated Additive Manufacturing (IAM), Politecnico di Torino, Corso Castelfidardo, 51, 10138 Torino, ItalyDepartment of Applied Science and Technology (DISAT), Politecnico Di Torino, Corso Duca degli Abruzzi 24, Torino 10129, Italy; Center of Integrated Additive Manufacturing (IAM), Politecnico di Torino, Corso Castelfidardo, 51, 10138 Torino, ItalyDepartment of Applied Science and Technology (DISAT), Politecnico Di Torino, Corso Duca degli Abruzzi 24, Torino 10129, Italy; Center of Integrated Additive Manufacturing (IAM), Politecnico di Torino, Corso Castelfidardo, 51, 10138 Torino, ItalyDepartment of Applied Science and Technology (DISAT), Politecnico Di Torino, Corso Duca degli Abruzzi 24, Torino 10129, Italy; Center of Integrated Additive Manufacturing (IAM), Politecnico di Torino, Corso Castelfidardo, 51, 10138 Torino, ItalyDepartment of Applied Science and Technology (DISAT), Politecnico Di Torino, Corso Duca degli Abruzzi 24, Torino 10129, Italy; Center of Integrated Additive Manufacturing (IAM), Politecnico di Torino, Corso Castelfidardo, 51, 10138 Torino, Italy; Corresponding authors at: Department of Applied Science and Technology (DISAT), Politecnico Di Torino, Corso Duca degli Abruzzi 24, Torino 10129, Italy (M. Lombardi).Department of Applied Science and Technology (DISAT), Politecnico Di Torino, Corso Duca degli Abruzzi 24, Torino 10129, Italy; Center of Integrated Additive Manufacturing (IAM), Politecnico di Torino, Corso Castelfidardo, 51, 10138 Torino, ItalyCurrently, laser and electron beam powder bed fusion (L/E-PBF) are prevalent in metal additive manufacturing (AM), demonstrating exceptional potential for producing copper (Cu) alloy components indispensable for numerous aerospace, automotive, energy, and marine applications. However, despite groundbreaking advances in metal AM, Cu alloys remain underdeveloped. This comprehensive review highlights the unremitting efforts to develop superior and bespoke L/E-PBF Cu alloy parts. Initially, roadblocks to Cu alloy printability are identified, along with solutions to surmount them, followed by feedstock development in the context of L/E-PBF. An extensive process-induced defect analysis is presented to assess the impact of powder feedstock characteristics, process parameters, and heat treatments. Furthermore, the mechanical, electrical, corrosion, and tribological properties of L/E-PBF-fabricated Cu alloy parts are elaborated to elucidate the nexus among material-microstructure-performance. In addition, this review delves into various strengthening mechanisms, the significance of post-processing heat treatment in stabilising non-equilibrium microstructures, and its influence on the material-property space. The discussion then extends to the importance of modelling for comprehending complex melt pool dynamics. Finally, the review uncovers lacunas and presents critical future research aspects to boost the technological readiness of L/E-PBF Cu alloys/composites for accelerated adoption.http://www.sciencedirect.com/science/article/pii/S0264127525001625Additive manufacturing reviewProcess parametersPowder bed fusionCopper alloysDefectsPost processing heat treatments |
| spellingShingle | Bhaskaranand Bhatt Alessandra Martucci Sara Biamino Daniele Ugues Federica Bondioli Laura Montanaro Mariangela Lombardi Paolo Fino Current trends in electron beam and laser powder bed fusion additive manufacturing of copper alloys: Composition, defects, properties, and challenges Materials & Design Additive manufacturing review Process parameters Powder bed fusion Copper alloys Defects Post processing heat treatments |
| title | Current trends in electron beam and laser powder bed fusion additive manufacturing of copper alloys: Composition, defects, properties, and challenges |
| title_full | Current trends in electron beam and laser powder bed fusion additive manufacturing of copper alloys: Composition, defects, properties, and challenges |
| title_fullStr | Current trends in electron beam and laser powder bed fusion additive manufacturing of copper alloys: Composition, defects, properties, and challenges |
| title_full_unstemmed | Current trends in electron beam and laser powder bed fusion additive manufacturing of copper alloys: Composition, defects, properties, and challenges |
| title_short | Current trends in electron beam and laser powder bed fusion additive manufacturing of copper alloys: Composition, defects, properties, and challenges |
| title_sort | current trends in electron beam and laser powder bed fusion additive manufacturing of copper alloys composition defects properties and challenges |
| topic | Additive manufacturing review Process parameters Powder bed fusion Copper alloys Defects Post processing heat treatments |
| url | http://www.sciencedirect.com/science/article/pii/S0264127525001625 |
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