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research article

Phase-separation-driven cracking in additive manufacturing of Ni-Cu alloy systems

Özsoy, Andaç  
•
Gaudez, Steve
•
Hearn, William A.
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July 25, 2025
Additive Manufacturing

This study investigates the cracking mechanism in additive manufacturing of Ni-Cu multi-material combinations using operando X-ray diffraction and imaging experiments during laser powder-bed fusion (L-PBF) of CuCrZr and IN625. It is shown that liquid immiscibility between the two alloy systems stems from the interaction between Cu and the alloying elements in IN625, causing both Cu-rich and Ni-rich liquids to form with different freezing ranges. Consequently, solidification cracking takes place due to the large solidification range where the Ni-rich solid and Cu-rich liquid co-exist. Guided by thermodynamic calculations, it was identified that the highest crack susceptibility occurs between 20 and 40 wt% CuCrZr-IN625, which was further validated by printing mixtures of the two alloys in different ratios. Operando X-ray imaging and scanning electron microscopy characterization revealed that the cracking occurred during the terminal stage of solidification. It was observed that the columnar grains of the Ni-rich primary solid separate into cracks, where Cu-rich liquid regions persist over a wide temperature range as the solidification of these regions begin significantly later. It was concluded that the mechanism of cracking explained in this study could be extended to other Cu-Ni alloy combinations containing elements that induce immiscibility when mixed with Cu during fusion-based processing methods.

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10.1016_j.addma.2025.104950.pdf

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Main Document

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Published version

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openaccess

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CC BY

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13.04 MB

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