The influence of laser powder bed fusion building parameters on the forming quality of CuCrZr alloy at the atomic scale

GY Li and Z Huang and JY Zhang and SW Wang and JY Xu and C Zhang and S Yin, OPTICS AND LASER TECHNOLOGY, 192, 113432 (2025).

DOI: 10.1016/j.optlastec.2025.113432

Laser powder bed fusion (LPBF) of CuCrZr alloys remains challenging due to their low laser absorptivity and high thermal conductivity. In this study, a combination of molecular dynamics (MD) simulations and experimental investigations are employed to optimize LPBF process parameters and elucidate the underlying atomic-scale evolution mechanisms. The simulations elucidate the melting and solidification behavior of powder particles and the mechanisms of defect formation under different processing conditions. The effects of laser power, scanning speed, and hatching distance on relative density, surface morphology, and microstructure evolution are systematically investigated. The effects of laser power, scanning speed, and hatch spacing on the density, crystal structure, and surface morphology of the material are investigated in this study. The optimal LPBF parameters of 380 W laser power, 500 mm/s scanning speed, and 0.07 mm hatching distance produce nearly fully dense parts with porosity below 0.1 %, consistent with MD simulation predictions.

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