Meaning
High-strength copper alloys combine excellent thermal and electrical conductivity with superior mechanical properties at elevated temperatures. Using copper chromium zirconium in additive manufacturing allows the production of complex conformally cooled tooling and high-heat flux components. This material retains its strength after heat treatment and resist softening during prolonged high-temperature exposure.
Alloy Composition
Achieving the optimal balance of properties requires precise control of the alloying elements during melting and consolidation. The addition of chromium and zirconium creates a precipitation-hardened microstructure that significantly enhances mechanical performance. Heat treatment, consisting of solution annealing and subsequent aging, is essential to maximize both hardness and conductivity.
Manufacturing Performance
Processing the alloy via laser powder bed fusion requires high laser power due to the material’s high reflectivity and thermal conductivity. Optimizing the print parameters minimizes porosity and ensures a density of over ninety-nine percent. This high density is critical for preventing premature thermal fatigue failures in service.
Tooling Application
Conformal cooling cores printed from this alloy are used in high-volume injection molding to reduce cycle times and control part temperature. The high thermal conductivity of copper chromium zirconium allows heat to be extracted from the plastic melt much faster than with standard tool steels. This acceleration increases throughput and prevents localized overheating, ensuring consistent part quality across millions of cycles and reducing the likelihood of part warpage.
