Abstract. Precipitation hardened Copper-Chromium-Zirconium alloy (CuCrZr, commercially known as C18150, CW106C) is widely used in various industries because of advanced thermal and mechanical properties. The common used technologies of CuCrZr alloy surface restoration (such as fusion welding, thermal spray. etc.) have significant limits and disadvantages that make it unacceptable for large scale components like continuous casting mold copper plates. In comparison the variation on solid state friction stir processing i.e. Friction Stir Additive Manufacturing (FSAM) provides the opportunity for scalability via layer by layer deposition by cover plate method. This study aimed to explore the potential of CuCrZr alloy surface build up to 10 mm thickness by multilayer FSAM process. Microstructural analysis, defects identification, thermal and mechanical properties evaluation were carried out. Structural transformation and microhardness distribution changes on FSAM and heat treatment (Solution, annealing and aging) were investigated. FSAM process parameters and non-consumable rotation tool design as well as underwater processing were studied to correlate the properties and microstructure to the functionalities that are desirable for large scale industrial application.