LPBF Parameter Optimization of Mechanical, Non-Thermal Generated C71500 Powder

This work investigates the optimization of Laser Powder Bed Fusion (LPBF) parameters for the C71500 copper-nickel alloy using mechanically produced, non-thermally generated powder. Utilization of this powder presents a more sustainable powder generation method through significant reduction in energy usage and CO2 emissions and a large array of alloys to be utilized within LPBF. A comprehensive design of experiments (DOE), with varying laser power and scan speed, was employed to construct a process performance map, which was subsequently refined using machine learning algorithms. Specimens fabricated under optimized conditions exhibited high dimensional fidelity, low surface roughness and porosity, and achieved relatively dense specimens. Mechanical testing confirmed that the optimized parameter sets exceeded standard wrought alloy values for ultimate tensile strength and yield strength, with almost meeting standard cast alloy values demonstrating feasibility of implementing common bar stock alloys in LPBF applications. The observed variability in tensile properties was attributed to inefficient laser parameters requiring further optimization. Future efforts will focus on repeating the optimization using quality powder controls and further refining tensile performance within the high-density region of the parameter space.