This study examined process–structure relationships in laser powder bed fusion of Al0.1CoCrFeNi + Cu composites, focusing on densification, elemental distribution, and solidification cracking. Mechanically mixed Al0.1CoCrFeNi and Cu powders were processed across a range of laser powers (100–250 W) and scan speeds (200–800 mm/s). Increased volumetric energy density (VED) improved densification, with a plateau near 200 J/mm3 yielding ~96% relative density; however, this value was still below application-grade thresholds. At low VED, insufficient thermal input and short melt pool residence times promoted Cu segregation, while higher VED facilitated improved elemental mixing. Elemental mapping showed partial co-segregation of Ni with Cu at low energies. Solidification cracks were observed across all processing conditions. In high VED regimes, cracking exhibited a minimal correlation with segregation behavior and was primarily attributed to steep thermal gradients, solidification shrinkage, and residual stress accumulation. In contrast, at low VED, pronounced Cu segregation appeared to exacerbate cracking through localized thermal and mechanical mismatch.

1. Introduction 
2. Experimental 
    2.1. Preparation of Mixed Al0.1CoCrFeNi + Cu composite powders 
    2.2. LPBF process of Al0.1CoCrFeNiCu Composite Mixture 
    2.3. Microstructure Characterization 
3. Results and Discussion 
    3.1 Cross-Sectional Analysis of LPBF-Fabricated Al0.1CoCrFeNiCu Composite Structures 
    3.2. Elemental Distribution Observation of Low and High VED Conditions 
5. Conclusion 
Funding 
Conflict of Interest 
Data Availability Statement 
Author Information and Contribution 
Acknowledgments
References

• Kwangtae Son(School of Mechanical, Industrial, and Manufacturing Engineering, Oregon State University, Corvallis, OR 97331, USA, Advanced Technology and Manufacturing Institute, Corvallis, OR 97330, USA) Corresponding author
• Somayeh Pasebani(School of Mechanical, Industrial, and Manufacturing Engineering, Oregon State University, Corvallis, OR 97331, USA, Advanced Technology and Manufacturing Institute, Corvallis, OR 97330, USA)
• Ji-Woon Lee(Division of Advanced Materials Engineering, Kongju National University, Cheonan 31080, Republic of Korea, Center for Advanced Materials and Parts of Powders, Kongju National University, Cheonan 31080, Republic of Korea)
• Soon-Jik Hong(Division of Advanced Materials Engineering, Kongju National University, Cheonan 31080, Republic of Korea, Center for Advanced Materials and Parts of Powders, Kongju National University, Cheonan 31080, Republic of Korea)