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Additive Manufacturing of Copper-Based Alloys
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Additive Manufacturing of Copper-Based Alloys

A special issue of Journal of Manufacturing and Materials Processing (ISSN 2504-4494).

Deadline for manuscript submissions: 30 September 2025 | Viewed by 1702

Special Issue Editor

Prof. Dr. Paul Bishop

E-Mail Website
Guest Editor
Net Shape Manufacturing Group, Department of Mechanical Engineering, Dalhousie University, Halifax, NS B3H 4R2, Canada
Interests: additive manufacturing of metallic materials; process development; material characterization
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Metal additive manufacturing (AM) has become a critical facet of the global advanced manufacturing enterprise. Commercialized applications for metal AM continue to emerge in many different sectors and involve a steadily broadening range of alloy systems. Copper-rich alloys feature prominently in this regard due to useful traits that include high electrical conductivity, exceptional strength, and outstanding corrosion resistance depending on the alloy system in question. This Special Issue seeks to publish fundamental and applied research related to the AM of these materials. Focal areas of interest include (but are not limited to) the following:

  • Production of feedstock materials for copper AM processing;
  • Copper alloy development for AM;
  • Processing of conventional copper alloy chemistries using AM;
  • Directed energy deposition of copper-rich alloys;
  • Laser powder bed fusion of copper-rich alloys;
  • Binder jet printing of copper-rich alloys;
  • Wire arc additive manufacturing of copper-rich alloys;
  • Properties of copper alloys processed through AM;
  • Use of non-conventional approaches and/or energy sources in the AM of copper alloys;
  • Effects of secondary operations on copper AM products;
  • Commercialized applications for copper AM products.

Prof. Dr. Paul Bishop
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Journal of Manufacturing and Materials Processing is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 1800 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • copper
  • copper alloys
  • additive manufacturing
  • alloy development
  • material characterization
  • secondary operations
  • commercial applications

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Published Papers (3 papers)

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Research

27 pages, 22019 KiB  
Article
Laser Powder Bed Fusion Processing of UNS C64200 Aluminum–Silicon–Bronze
by Kenzie A. Timmons, Ali Nasiri and Donald P. Bishop
J. Manuf. Mater. Process. 2025, 9(5), 147; https://doi.org/10.3390/jmmp9050147 - 30 Apr 2025
Viewed by 116
Abstract
This research focused on developing the processing parameters required to fabricate UNS C64200 aluminum–silicon–bronze (ASB) using laser powder bed fusion (LPBF) additive manufacturing. A full factorial design of experiments (DOE), followed by a central composite DOE, was employed to statistically optimize the as-built [...] Read more.
This research focused on developing the processing parameters required to fabricate UNS C64200 aluminum–silicon–bronze (ASB) using laser powder bed fusion (LPBF) additive manufacturing. A full factorial design of experiments (DOE), followed by a central composite DOE, was employed to statistically optimize the as-built density while varying laser power, scan speed, and hatch spacing. Parameter sets that yielded high-density (>99.9%) products were then utilized to manufacture specimens to determine mechanical properties in both the as-built and heat-treated states. The as-built samples exhibited high tensile strength but relatively low ductility and absorbed impact energy, owing to the presence of a mixed α/β’ microstructure. Heat treatment at 620 °C eliminated the martensitic β’ phase, which manifested significant gains in ductility and absorbed energy. As such, the final tensile properties and impact toughness exceeded the Defence Standard minimum requirements for conventionally processed ASB. Full article
(This article belongs to the Special Issue Additive Manufacturing of Copper-Based Alloys)
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26 pages, 3292 KiB  
Article
Additive Manufacturing of Copper—A Survey on Current Needs and Challenges
by Moritz Benedikt Schäfle, Michel Fett, Julian Gärtner and Eckhard Kirchner
J. Manuf. Mater. Process. 2025, 9(4), 109; https://doi.org/10.3390/jmmp9040109 - 27 Mar 2025
Viewed by 529
Abstract
Additive manufacturing (AM) of copper is subject to dynamic development regarding available processes and the quality of produced parts. While challenging, AM processes for copper provide parts with a quality comparable to other metallic material groups like steels. The reasons for the lower [...] Read more.
Additive manufacturing (AM) of copper is subject to dynamic development regarding available processes and the quality of produced parts. While challenging, AM processes for copper provide parts with a quality comparable to other metallic material groups like steels. The reasons for the lower prevalence of additive manufacturing of copper components in industrial applications are currently not sufficiently researched, especially in light of the significant progress made in the maturity of this technology. A survey is used to investigate the assessments of protagonists in the field of copper AM. The needs of current and potential users of copper AM are analyzed and outlined. This study reveals that the most relevant technical limitation for users is the reduced surface quality of parts, while overall processes need to become less costly and more reliable to find broader use. Answers given hint to a higher degree of automation, the possibility of multi-material processing, and the upscaling of machine and part sizes as relevant future trends in the copper AM sector. Full article
(This article belongs to the Special Issue Additive Manufacturing of Copper-Based Alloys)
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15 pages, 3138 KiB  
Article
Casting Homogeneity of Scaled-Up Multiprincipal Component Alloys
by Gbenga. J. Adeyemi, Claire Utton, Yunus Azakli and Russell Goodall
J. Manuf. Mater. Process. 2025, 9(2), 41; https://doi.org/10.3390/jmmp9020041 - 29 Jan 2025
Viewed by 635
Abstract
High-entropy and multicomponent alloys are believed to offer opportunities for improved properties and are currently of great interest to the research community. Studies on these materials are largely conducted on small samples, but, for many practical applications, larger-scale processing would be needed. The [...] Read more.
High-entropy and multicomponent alloys are believed to offer opportunities for improved properties and are currently of great interest to the research community. Studies on these materials are largely conducted on small samples, but, for many practical applications, larger-scale processing would be needed. The processing of metallic parts of high dimensionality conventionally begins with casting, but an increase in the scale of the melt increases the potential for effects dependent on segregation, diffusion and thermal transport. The objective here is to determine the effect of scale-up on the as-cast condition of an example multicomponent alloy, Cu-Zn-Mn-Ni medium-entropy (ME) brass, in a larger quantity. The ingot was produced by metallic mould casting after induction melting. The hardness, microstructures and chemical composition were assessed in the as-cast state across a section through the material. A range of hardness values were found, particularly in the vertical direction, where the upper region was found to have a hardness of 188 ± 15 HV0.5, a middle of 161 ± 11 HV0.5 and a bottom of 184 ± 16 HV0.5. These values can be correlated with the casting conditions experienced locally, but the average hardness values are close to that of the original reports of the alloy. To overcome this, it is likely that a heat treatment would need to be used for this alloy in practical production before the products could be applied for engineering uses. Full article
(This article belongs to the Special Issue Additive Manufacturing of Copper-Based Alloys)
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