Multi-scale Cu-Cr composites using elemental powder blending in laser powder-bed fusion

Cu-Cr-based alloys are good candidates for thermo-electrical applications because of their excellent combination of mechanical, thermal, and electrical properties. However, tailoring their microstructure via traditional processes such as sintering and casting remains a challenging task. Herein, we introduce a strategy to fabricate multiscale Cu-25Cr composites. This is achieved through in-situ alloying from elemental powder blending in laser powder-bed fusion. The process is monitored layer-by-layer using synchrotron X-ray microtomography. We show that by changing the melt-pool size and its overlap, one can produce multiscale Cu-Cr composites with coarse (similar to 50 mu m) and fine Cr-spheroids (<500 nm) while controlling their spatial distribution. Coarse Cr particles are preferentially located at the melt pool boundaries while fine spherical Cr particles are distributed in the melt pool interior. Spatial variations in mechanical properties are revealed using nanoindentation mapping. This strategy opens new opportunities to optimize multiscale metal matrix composite through the manipulation of the scanning strategy.