Laser powder bed fusion of CuCr1Zr on 316 L: a simplified methodology to unravel the effect of intermixing and energy input in the first interfacial layer

Abstract Multi-material laser powder bed fusion (PBF-LB) enables the fabrication of complex components, but presents challenges in material compatibility at interfaces. This study investigates the interface formation between 316 L steel and CuCr1Zr, a promising combination for heat exchanger applications. A simplified approach is adopted by printing single layers of CuCr1Zr within steel cavities using standard PBF-LB equipment. A process window for the first interfacial layer is established, demonstrating that increased layer thickness (2–4 times the standard) limits intermixing. Despite achieving a 14.2 mm-long interface with only 0.7 % cracking in steel, copper contamination cracking (CCC) remains a critical issue, as revealed by microstructural analyses using Energy-Dispersive X-ray Spectroscopy (EDS) and Electron Backscatter Diffraction (EBSD). These findings highlight fundamental limitations in achieving crack-free interfaces over extended lengths, questioning the feasibility of multi-material PBF-LB for certain applications.