The surface morphologies and internal pores evolution of a CuSn10 alloy fabricated by laser powder bed fusion

The fabrication of high quality copper alloys using laser powder bed fusion (LPBF) technology remains challenging due to their low laser absorption and high thermal conductivity. LPBF often involves intrinsic defects, such as rough surface and internal pores, which largely deteriorate the performance of as-built copper alloy components. Here we studied the effect of scanning speed on the evolution of surface morphologies and internal pores of LPBF-fabricated CuSn10 alloy. The melt flow behaviors were studied by both experiments and in situ observations where combined a high-speed camera with an infrared thermal imager. With increasing the scanning speed, the morphology of melt track evolves from a continuous track to a discontinuous one, whereas the internal defects change from a great number of spherical pores to many irregular pores. A higher scanning speed decreases the peak temperature of the melt pool and causes less overlaps between neighboring melt tracks, thus deteriorating wetting behaviors. It is expected that the obtained results are beneficial for guiding the additive manufacturing of copper alloy parts with high metallurgical quality and thus promoting their industrial applications.