Mechanical Characterization of Additively Manufactured C103

Abstract With the growing demand for lightweight, high-performance components in the aerospace and defense sector, additive manufacturing has become a key enabler for design freedom and material efficiency. Laser-based powder bed fusion of metals offers the ability to produce complex, near-net-shape parts with minimal material waste and high customization potential. Despite these advantages, challenges remain, particularly regarding process-induced defects, anisotropic mechanical properties, and internal residual stresses, which may critically influence the fatigue behavior and long-term reliability of components.This study presents a comprehensive mechanical characterization of C103, a niobium-based alloy that is valued for its high-temperature strength and good formability, but which exhibits limited intrinsic oxidation resistance at elevated temperatures and therefore requires suitable protective coatings for operation in oxygen-rich environments. Because of its favorable mechanical stability at high temperatures and its compatibility with diffusion-based silicide coatings, C103 is frequently considered for thruster and propulsion components in space applications. Tensile tests show great ductile material behavior and good repeatability.Cyclic hardening was evaluated in fatigue tests. Overall, a good comparability to conventionally manufactured C103 was measured, enabling highly complex structures for aerospace and defense applications.