Effect of Process Parameters on the Microstructure and Properties of Ti15Zr5Cu Alloy Fabricated via Selective Laser Melting

doi:10.1007/s40195-025-01896-0

Abstract

Abstract:

Ti-Zr-Cu alloy has garnered significant attention in the field of dental implants due to its excellent biocompatibility, antibacterial properties, and potentially controllable mechanical properties. However, two critical challenges remain in the selective laser melting (SLM) fabrication of Ti-Zr-Cu alloy: First, the high thermal conductivity of the Cu element tends to destabilize the solidification behavior of the molten pool, leading to uncontrollable pore defect evolution; Second, the influence of process parameters on the synergistic effects of zirconium solution strengthening and copper precipitation strengthening is not well understood, hindering precise control over the material's mechanical properties. To address these issues, this study systematically elucidates the quantitative impact of energy input on the defect formation mechanisms and strengthening effects in the SLM processing of Ti15Zr5Cu alloy. By optimizing laser power (120-200 W) and scanning speed (450-1200 mm/s) through a full-factor experimental design, we comprehensively analyze the effects of energy input on defect morphology, microstructure evolution, and mechanical performance. The results demonstrate that as energy density decreases, defect types transition from spherical pores to irregular pores, significantly influencing mechanical properties. Based on the defect evolution trends, three distinct energy density regions are identified: the high-energy region, the low-energy region, and the transition region. Under the optimal processing conditions of a laser power of 180 W and a scanning speed of 1200 mm/s, the Ti15Zr5Cu alloy exhibits a relative density of 99.998%, a tensile strength of 1490 ± 11 MPa, and an elongation at break of 6.0% ± 0.5%. These properties ensure that the material satisfies the stringent requirements for high strength in narrow-diameter implants used in the maxilloanterior region. This study provides theoretical and experimental support for the process-property optimization of Ti-Zr-Cu alloys in additive manufacturing and promotes their application in the fabrication of high-performance, antibacterial dental implants.

Key words: Selective laser melting, Ti15Zr5Cu, Defect type, Process parameters, Mechanical property

Yao-Zong Mao, Ya-Hui Zhang, De-Chun Ren, Diao-Feng Li, Hai-Bin Ji, Hai-Chang Jiang, Chun-Guang Bai. Effect of Process Parameters on the Microstructure and Properties of Ti15Zr5Cu Alloy Fabricated via Selective Laser Melting[J]. Acta Metallurgica Sinica (English Letters), 2025, 38(10): 1699-1710.

Figures/Tables 15

Fig. 1 Ti15Zr5Cu alloy powder: a powder morphology; b particle size distribution

Fig. 2 Schematic diagram of laser scanning strategy for SLM forming process

Fig. 3 Ti15Zr5Cu samples prepared by SLM method: a Ti15Zr5Cu cylinders prepared with different process parameters (layer thickness 0.03 mm, scanning spacing 0.09 mm); b tensile specimen

Table 1 Development of 30 process parameters in the SLM processing of Ti15Zr5Cu alloy

Sample set	Laser power (W)	Scan speed (mm/s)	Energy (J/mm³)	Sample set	Laser power (W)	Scan speed (mm/s)	Energy (J/mm³)
1	120	450	98.8	16	180	900	74.1
2	120	600	74.1	17	180	1050	63.5
3	120	750	59.3	18	180	1200	55.6
4	120	900	49.4	19	210	450	172.8
5	120	1050	42.3	20	210	600	129.6
6	120	1200	37.0	21	210	750	103.7
7	150	450	123.5	22	210	900	86.4
8	150	600	92.6	23	210	1050	74.1
9	150	750	74.1	24	210	1200	64.8
10	150	900	61.7	25	240	450	197.5
11	150	1050	52.9	26	240	600	148.1
12	150	1200	46.3	27	240	750	118.5
13	180	450	148.1	28	240	900	98.8
14	180	600	111.1	29	240	1050	84.7
15	180	750	88.9	30	240	1200	74.1

Fig. 4 Distribution of defects in SLM-formed Ti15Zr5Cu alloy: a cross-section; b longitudinal section

Fig. 5 Relation between laser power and scanning speed and relative density of samples: a front view; b input energy density versus relative density; c five groups of samples with higher relative density

Fig. 6 Parameters of SLM forming and machining of Ti15Zr5Cu alloy

Fig. 7 Schematic diagram of various internal defects in SLM-formed Ti15Zr5Cu alloy: a morphology of spherical regular defects (120 W, 450 mm/s); b morphology of irregular defects (120 W, 900 mm/s); c principle of SLM; d formation process of spherical regular defects; e formation process of irregular shape defects

Fig. 8 3D optical micrograph of melt pool morphology of SLM-formed Ti15Zr5Cu alloy sample

Fig. 9 OM and SEM micrographs of SLM-formed Ti15Zr5Cu alloy samples: a, b cross-section; c-f longitudinal section

Table 2 Process parameters employed in the SLM formation of tensile specimens from the Ti15Zr5Cu alloy

Sample	P (W)	v (mm s⁻¹)	E (J mm⁻³)
S1	120	450	98.8
S4	120	900	49.4
S12	150	1200	46.3
S18	180	1200	55.6
S24	210	1200	64.8

Fig. 10 Influence of defect types and proportion ratios on the tensile properties of Ti15Zr5Cu alloy at room temperature: a stress-strain curves for samples S1, S4, and S18; b relationships between ultimate tensile strength (UTS), yield strength (YS), and elongation (EL) for samples S1, S4, and S18

Fig. 11 Influence of defect types and proportion ratios on the tensile properties of Ti15Zr5Cu alloy at room temperature: a stress-strain curves for samples S12, S18, and S24; b relationships between ultimate tensile strength (UTS), yield strength (YS), and elongation (EL) for samples S12, S18, and S24

Fig. 12 Effect of defects on the morphology of tensile fracture at room temperature of specimens of the Ti15Zr5Cu alloy

Fig. 13 Effect of laser power on the tensile fracture morphology of specimens of the Ti15Zr5Cu alloy at room temperature

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