Enabling Invar to Ti6Al4V transitions through copper in functionally graded laser powder bed fused components

This study examines the microstructural evolution, elemental distribution, phase composition, and hardness variations in multi-material samples fabricated using Laser Powder Bed Fusion (LPBF) with Invar and Ti6Al4V with compositional gradients mediated by copper. A range of compositional transitions from Invar to Ti6Al4V with different copper fractions are reported. Defects such as gas and keyhole pores were detected in well-deep keyhole mode areas, while lack of fusion defects were observed in samples with pure Cu interlayers due to poor wettability and processing parameter variations. Crack formation between interlayer gradient zones and Invar regions was linked to FeNi and CuNi intermetallic phases. Intermetallic compounds (e.g., FeNi, CuNi, TiFe, TiNi) significantly influenced the microstructure and mechanical performance. Vickers hardness testing shows varying hardness across different builds, with the highest hardness being observed in the gradient zone enabled by pure copper (approximately 620 HV). This study also underscores the need for tailored component design linking build processing parameters and compositional transitions in multi-material LPBF to achieve desired properties and component structural behaviour. • Functionally graded material Invar-Copper-Ti6Al4V is successfully built using laser powder bed fusion. • Different content of Cu and the influence on microstructure and mechanical properties are investigated. • Complex microstructures and intermetallics determine mechanical properties, tailoring build quality.