Abstract
In this investigation, the characteristics of two sets of rapidly solidified aluminum alloy powders were compared, and correlations between powder characteristics and mechanical properties of extrusions fabricated from the powders were examined. Rapidly solidified 7091 and PM64 aluminum alloy powders were characterized in terms of powder morphologies, powder sizes and size distributions, dendritic cell sizes, thicknesses of surface oxide films, and oxygen contents. The analytical techniques used for powder characterization consisted of automated image analysis, scanning electron microscopy, optical metallography, Auger electron spectroscopy, and neutron activation analysis. It was determined that Alloy 7091 powders (atomized in air) and Alloy PM64 powders (atomized in nitrogen-oxygen environments) had similar powder characteristics, such as powder surface morphologies, size distributions, and microstructures. However, these two types of atomization produced differences in surface oxide chemistry and oxygen content. Extrusions fabricated from coarse powders had properties equivalent to those of extrusions from finer powders. No other correlations were observed between mechanical properties and powder characteristics.
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