Open Access

Heinrich von Lintel, Katrin Jahns, Ulrich Krupp

• Additive manufacturing of CuCr1Zr demonstrates significant potential for industrial applications, particularly in the field of e-mobility. This paper describes the process chain and key factors involved. Suitable raw material for laser-based powder bed fusion can be produced via close-coupled gas atomization. Using argon at a pressure of 0.8 MPa, spherical particles of up to 200 µm can be achieved. After sieving and air separation, a particle size distribution in the range from 20 µm to 60 µm was measured. Samples manufactured using a green qcw-laser exhibit a higher microhardness of 220 HV0.1 compared to conventional CuCr1Zr or samples produced with a red cw-laser. Based to the greater geometric flexibility of additive manufacturing, internal cooling inlets can be integrated into pin contacts, significantly reducing temperature increases during the application of charging currents up to 300 A. This effect is further enhanced by applying a silver coating to the contact. After water injection, no further temperature increase is observed.