Correlation between Local and Bulk Scale Mechanical Properties of Additive Manufactured GRCop-42 and GRCop-84 Alloy

Additively manufactured (AM) copper alloys have exhibited a growing potential for industrial utilization. Their versatile capabilities allow for their used across various industries, ranging from rocket engine combustion chambers to marine equipment such as propellers and pumps. However, the unique characteristics of the additive manufacturing process, such as the layer-by-layer build method, large thermal gradients, and cooling rates, lead to distinct material properties compared to their conventionally manufactured counterparts. Consequently, a thorough regimen of testing and characterization is essential to guarantee the production of components with reliable properties, ensuring safe and effective operations. The current investigation specifically focuses on laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) techniques for fabricating GRCop-42 and GRCop-84 samples. A comprehensive examination has been undertaken to elucidate the relationship between micro/nanoscale and macro-scale properties and microstructural features, with a focus on correlating small-scale hardness with tensile properties. Furthermore, the study provides detailed insights into several indentation-based quantitative variables, including the plasticity index, elastic recovery, recovery resistance, and wear resistance index of the L-PBF and LP-DED materials. Through an exhaustive analysis of these factors, this research contributes significantly to enhancing our understanding of the hardness-strength relationship and the associated material properties.