Influence of laser powder bed fusion process parameters on the properties of CuZn42 components: case study of the laser surface energy density

Although additive manufacturing (AM) technologies have been rarely used to produce lead-containing brass, the same AM technologies have never been adopted to produce lead-free brass parts based on the CuZn42 alloy. This study aims to fill the gap, demonstrating the feasibility of lead-free brass alloys by laser powder bed fusion (LPBF) technology and investigating structural and mechanical properties of the produced specimens, focusing attention on the role of surface energy density on material properties. Starting from a raw powder of CuZn42 alloy containing α, β and γ brass phases, fully dense samples with high hardness values were obtained by LPBF. The structural and mechanical properties of the samples were investigated by scanning electron microscopy (SEM), energy-dispersive microanalysis (EDS), X-ray diffraction (XRD) and density and hardness measurements. Results showed that density, hardness and the relative amount of the brass phases depend on the surface energy density (SED) E_s. The investigated range of SED allowed defining the process window ranging from 2 J/mm² to 10 J/mm², within which fully dense samples can be obtained. A linear dependence of hardness on density was also found, suggesting that deformation mechanisms are mainly due to the presence of residual pores and internal cavities rather than to microstructural features, such as the relative amount of brass phases and crystallographic defects. All results obtained in this work demonstrated, for the first time, that LPBF is suitable to produce components based on the CuZn42 alloy, and that structural and mechanical properties of the produced parts can be properly designed by controlling SED.