Jewellery design enabled by customized 3D printing of Ag and Au–Ag–Cu alloys: process and microstructural optimization
摘要
Additive manufacturing (AM) of silver (Ag) and Au–Ag–Cu alloys offers significant potential for jewellery and biomedical applications, yet challenges such as porosity, residual stress and corrosion susceptibility remain. This study investigates the independent and combined effects of four laser processing parameters: power (80–200 W), scan speed (600–1200 mm s−1), hatch spacing (80–120 µm) and layer thickness (20–40 µm) on microstructural evolution, mechanical behaviour and corrosion resistance in selectively laser melted noble metals. Using a full-factorial design (n = 192 builds), microstructure was analyzed via EBSD and FIB-CT, mechanical performance via nanoindentation and tensile tests, and corrosion resistance through EIS and XPS. Regression models, PCA, and Scheil–Gulliver simulations were used to interpret interactions. Key findings include reduced Ag grain size (–0.51 µm) and increased hardness (+4.12 HV) with higher laser power, while faster scan speeds increased porosity. Optimized volumetric energy density (>100,000 J mm–3), enhanced pore sphericity, and reduced porosity, while corrosion rates dropped by ~26% and charge transfer resistance increased by ~20%. These results demonstrate how careful tuning of AM parameters can enhance strength, corrosion behaviour, and structural reliability, providing a pathway toward customized, high-performance precious metal components with minimized post-processing requirements.