Due to their outstanding electrical and thermal conductivity properties copper (Cu) and Cu alloys represent one of the major groups of commercial metals with respect to production and consumption. However, the low strength of pure copper is always referred to as the main drawback. The copper alloy CuCrZr represents one of the candidates to satisfy the strength limitations by aging heat-treatments. Conventional manufacturing of CuCrZr by casting and machining becomes extremely challenging and cost-intensive when machining of complex precision components, e.g. cooling channels in heat transfer elements, is required. Thus, the identification of other processing routes, such as Laser-Based Powder Bed Fusion (PBF-LB), can be seen as a crucial step towards a time and cost efficient production of CuCrZr parts.

Thus, the current study focusses on the influence of heat treatments on the microstructure and mechanical properties, especially in the low-cycle fatigue regime, of CuCrZr processed by PBF-LB. Results are discussed based on microstructural investigations (by scanning electron microscopy (SEM) and computed tomography (CT)) as well as on fracture surface analysis, providing novel insights on the role of geometrical parameters to the process window allowing for robust and reliable establishment of solid structures.