Evaluation of the Fatigue Performance of Pure Copper Manufactured by Electron Beam Powder Bed Fusion (EB-PBF)
Evaluation of the Fatigue Performance of Pure Copper Manufactured by Electron Beam Powder Bed Fusion (EB-PBF)
Tuesday, October 21, 2025: 9:00 AM
The extensive industrial application of copper in electronics, thermal systems, and aerospace has drawn increased interest in employing additive manufacturing (AM) to fabricate metallic components with complex internal structures. Electron beam powder bed fusion (EB-PBF) has emerged as the most suitable technology for additively producing complex high-purity copper components with a remarkable relative density of 99.95% while maintaining outstanding mechanical, thermal, and electrical properties compared to other AM fabrication routes. However, very limited research has focused on the fatigue property of pure copper material produced via the EB-PBF route, a crucial factor given the copper component’s susceptibility to progressive structural failure under cyclic loading and high pressure. This study investigates the fatigue response of EB-PBF copper components by conducting stress-based fatigue testing on samples fabricated in three build orientations (0°, 45°, and 90°), both in the as-fabricated status and after hot isostatic pressing (HIP) post-processing. The results reveal that horizontally built (90°) samples exhibit the highest fatigue life, followed by vertically built (0°) samples, while diagonally built (45°) samples show the lowest fatigue resistance. Key factors influencing the material’s fatigue performance including microstructural variations, process-induced defects, stress amplitude, and post-processing treatments are also discussed.