Optimizing processing parameters in electron beam powder bed fusion(EB-PBF) for CuNiFeSnTi/Diamond composites

Additive manufacturing enables structural-functional integration of metal matrix diamond composites, while the poor formability and thermal damage to diamond under high-temperature melt pools needs to be solved. In this work, CuNiFeSnTi/Diamond composites were prepared by an electron beam powder bed fusion (EB-PBF) method. The strategies of manipulating processing conditions, in order to control both the metallurgical quality of the composites and thermal stability of diamond, were investigated. The modified normalized enthalpy and lack of fusion parameters are proposed to accelerate the optimization of process parameters to prevent metallurgical porosity. The high activation energy for diamond in vacuum is helpful to expand the processing window. Within the energy density range of 27.43–28.8 J/mm 3 , CuNiFeSnTi/diamond composites with high density and controllable graphitization can be manufactured, and the transverse rupture strength (TRS) of the composites is as high as 809 MPa. This represents the highest value reported to date for Cu alloy diamond composites in powder bed fusion technology. • CuNiFeSnTi/diamond composites with high density and controllable graphitization were manufactured. • CuNiFeSnTi/diamond composites exhibit the highest transverse rupture strength (809 MPa). • The modified normalized enthalpy and lack of fusion parameters can effectively optimize the EB-PBF process.