Al–Si–Cu and Al–Si–Cu–Ni alloys for additive manufacturing: composition, morphology and physical characteristics of powders

Abstract

Novel Al–Si–Cu and Al–Si–Cu–Ni powders for additive manufacturing were studied. The powders were produced by molten alloys spraying in nitrogen. The following initial requirements of powder quality were assumed for its selective laser melting (3D printer SLM–280): a spherical shape of particles; an absence of non-metallic impurities; an excellent powder fluidity; the average particle size is 10–63 μm. Chemical composition, morphology and physical characteristics of the powders were comprehensively studied. According to EDX data, the powders did not contain non-metallic impurities. Shape of particles was examined as well: more than 70% of the particles were spherical. Particle size distribution and average particle size were studied. The average particle size was in the range of 40–45 μm. Al–Si–Cu powder fluidity was different from those for Al–Si–Cu–Ni powder: 24.5 s versus 38 s due to the presence of more non-spherical particle in the second powder. The studied powders have excellent properties to be uses as a raw material for 3D printing by selective laser melting. The characteristics of the studied powders were close to the most common composition for 3D printing AlSi10Mg.