Testing of manufacturability and characterization of bimetallic material of Inconel 718 and CuCrZr fabricated by laser-based powder bed fusion

Abstract

Laser-based powder bed fusion of metals (PBF-LB/M) is an additive manufacturing technique in which metal powder is fused layer-by-layer to form three-dimensional components. PBF-LB/M has been established as a manufacturing method for producing complex components otherwise non-viable or impossible to manufacture. The interest in multi-material PBF-LB/M, which allows for combining desired properties of two or more metal materials in one component, has increased as the technology has developed. This thesis explores the manufacturing of a bimetallic material combination of Inconel 718 (IN718) and copper-chromium-zirconium alloy (CuCrZr) using PBF-LB/M to find optimised process parameters supported by different material characterisation and testing methods. In addition, the effects of heat treatment on the properties of the manufactured material are studied. The process of manufacturing the bimetallic material combination of IN718 and CuCrZr lacks research, and this thesis aims to successfully manufacture a defect free bimetallic material. The results obtained in this thesis showed promise for manufacturing of defect-free bimetallic material of IN718 and CuCrZr. Bimetallic material was successfully manufactured, and the quality of the material was tested and analysed. The compatibility of IN718 and CuCrZr was proven as the materials exhibited mixing at the interface zone allowing for bonding between the two materials. However, some defects were observed in the materials which require further studies and optimisation of the manufacturing process and post-processing steps. The effects of additional optimisation of the manufacturing process parameters on the number of defects found in the material should be studied. In addition, the heat- treatment process should be further developed to match the requirements of the bimetallic material combination