Effect of LPBF Process Parameters on Thermomechanical Properties of a Copper-Based Metal Matrix Composite

This study explores the application of laser powder bed fusion (LPBF) technology for fabricating metal matrix composites (MMCs) tailored for liquid rocket engine thrust chambers. The focus is on Cu174PH8020, a blend of 80% copper and 20% 17-4PH stainless steel, examined to ascertain the optimal volumetric energy density (VED), which ensures the highest quality of the produced MMC. Extensive experimentation assessed the impact of varying body VED (from 77.6 J/mm3 to 111.1 J/mm3) and contour VED (from 160 J/mm3 to 266.6 J/mm3) values on the material’s mechanical and thermal properties, including density, hardness, thermal conductivity, and Young’s modulus, across a range of process parameters and temperatures. The results indicate that a VED of approximately 99.2 J/mm3 maximizes the material properties, achieving a relative density of 99,65% and substantial mechanical hardness while maintaining favorable thermal conductivity. Compared to traditional aerospace alloys such as nickel-based superalloys and other copper alloys, Cu174PH8020 demonstrates competitive thermal and mechanical properties under optimized conditions. These findings suggest that when processed under these conditions, Cu174PH8020 holds significant potential for aerospace applications, offering a balanced profile of mechanical strength and thermal performance.