Evolution Mechanism of Microstructure and Electrical Conductivity of Laser Directed Energy Deposition (TC4 + TiC)/CuCrZr Under Electroshock Treatment

This study addresses issues such as cracking and deterioration of electrical conductivity in laser directed energy deposition (LDED) on copper alloy surfaces, proposing a synergistic process combining surface pretreatment with electroshock treatment (EST). An Ti‐6Al‐4V(TC4) + TiC composite coating was manufactured on a CuCrZr substrate via LDED. The effects of three substrate surface conditions—cold‐sprayed Ti, shot peening, and unprocessed—on the interfacial bonding quality of the cladding layer were systematically investigated. Analyzing EST mechanisms for enhancing interfacial microstructure reconstruction and electrical conductivity. The results indicated that the cold‐sprayed Ti pretreatment, by providing a transition layer, achieving the most continuous and dense bonding interface. EST significantly promoted the interdiffusion of Cu and Ti elements at the interface, widening the transition zone. The microscopic electrical resistance of the sample treated with EST for 0.1 s showed a maximum reduction of 69.09%, because of EST induced fragmentation and spheroidization of the continuous brittle Cu–Ti intermetallic compounds (IMCs) layer, promoted the precipitation of fine and dispersed Cu ₄ Ti phases, increased lattice distortion, and healed microcracks. This research provided a novel technological approach and theoretical basis for manufacturing high‐strength, high‐conductivity titanium matrix composites (TMCs) coating on copper alloys.