A nuclear Zr-4 alloy with a near full density was fabricated via laser powder bed fusion (LPBF). The influences of process parameters on the printability, surface roughness, and mechanical properties of the LPBF-printed Zr-4 alloy were investigated. The results showed that the relative density of the Zr-4 alloy samples was greater than 99.3% with the laser power range of 120-160 W and the scanning speed range of 600-1000 mm/s. Under a moderate laser power in the range of 120-140 W, the printed Zr-4 alloy possessed excellent surface molding quality with a surface roughness less than 10 µm. The microstructure of the printed Zr-4 alloy was an acicular α phase with an average grain size of about 1 µm. The Zr-4 alloy printed with a laser power of 130 W and a scanning speed of 400 mm/s exhibited the highest compression strength of 1980 MPa and the highest compression strain of 28%. The findings demonstrate the potential in the fabrication of complex Zr-4 alloy parts by LPBF for industrial applications.
Keywords: Zr-4; additive manufacturing; laser powder bed fusion; process optimization; zirconium alloys.