Powder Additive Manufacturing Research Articles

Life cycle assessment in additive manufacturing of copper alloys—comparison between laser and electron beam

AbstractAdditive manufacturing is becoming increasingly important for industrial production. In this context, directed energy deposition processes are in demand to achieve high deposition rates. In addition to the well-known laser-based processes, the electron beam has also reached industrial market maturity. The wire electron beam additive manufacturing offers advantages in the processing of copper materials, for example. In the literature, the higher energy efficiency and the resulting improvement in the carbon footprint of the electron beam are highlighted. However, there is a lack of practical studies with measurement data to quantify the potential of the technology. In this work, a comparative life cycle assessment between wire electron beam additive manufacturing (DED-EB) and laser powder additive manufacturing (DED-LB) is carried out. This involves determining the resources for manufacturing, producing a test component using both processes, and measuring the entire energy consumption. The environmental impact is then estimated using the factors global warming potential (GWP100), photochemical ozone creation potential (POCP), acidification potential (AP), and eutrophication potential (EP). It can be seen that wire electron beam additive manufacturing is characterized by a significantly lower energy requirement. In addition, the use of wire ensures greater resource efficiency, which leads to overall better life cycle assessment results.

Closed Circuit of 3-Dimensional Polymer Powders

This article describes the most important stages of testing the levels of innovative readiness of a new machine and material construction solutions for closed loops of polymer powders in 3D additive manufacturing. The aim of this study was to indicate the state and directions of development of the technology of geometric recycling of polymer powders in 3D additive manufacturing, the need to control the geometric quality of the powders, and the quality of the design of machines for their processing in a closed circuit. The method was aimed at creating a strategy and verifying the stages of development of a new idea for stabilizing the geometric and dynamic design features of polymer powders for additive manufacturing (3D printing). Connections and relationships of the variable design features of powders, machines and devices with variable postulated states of products and processes allowed for the analysis, knowledge, description and development of variables for stabilizing geometric features of polymer powders in recycling. The results show the possibilities of supporting innovative creativity according to the adopted method, allow for determining the level of compliance of the quality of the products of the technical system, the effectiveness of preparatory processes for recycling and the non-toxicity of the products and processes of the new technology and their closed loop. The goal of developing useful design values, according to an integrated method of analysis, assessment and environmental development, was achieved, including the proposal of design features of razor blade shredders, supported by genetic algorithms, and devices for stabilizing polymer powders in additive manufacturing with recycling.

Shape effects in binary mixtures of PA12 powder in additive manufacturing

The quality of powder spread in additive manufacturing devices depends sensitively on particle shapes. Here, we study powder spreading for mixtures of spherical and irregularly shaped particles in Polyamide 12 powders. Using DEM simulations, including heat transfer, we find that spherical particles exhibit better flowability. Thus, the particles are deposited far ahead of the spreading blade. In contrast, a large fraction of non-spherical particles hinders the flow. Therefore, the cold particles are deposited near the front of the spreading blade. This results in a temperature drop of the deposited particles near the substrate, which cannot be seen with spherical particles. The particles of both shapes are homogeneously distributed in the deposited powder layer.

Synergistic impact mechanism of particle size and morphology in superalloy powders for additive manufacturing

The particle size and morphology of superalloy powders are crucial parameters that significantly influence the performance of additive manufacturing (AM) processes. This study investigates the effects of atomization pressure on these characteristics through a combination of computational fluid dynamics (CFD) simulations and vacuum induction melting gas atomization (VIGA) experiments. The CFD simulations revealed that increasing the atomization pressure from 2.0 MPa to 3.5 MPa resulted in a rise in maximum gas velocity from 526 m/s to 537 m/s and a reduction in median particle size (D50) from 60.9 μm to 37.5 μm. Subsequent experiments demonstrated a decrease in D50 from 52.9 μm to 35.6 μm, and sphericity from 0.9432 to 0.9377, as pressure increased. The particle size results of the atomization experiments and numerical simulations show strong consistency, validating the accuracy of the numerical simulation results. The volume of hollow particles also increased slightly in specific size fractions. These results suggest that higher atomization pressures produce finer powders with lower sphericity, but also promote particle adhesion, reducing the overall refinement effect. This study provides insights into optimizing atomization conditions for the precise control of superalloy powders in AM.

Effect of Particle Size, Lubricant, and Heat Temperature on the Flowability of Ni-Based Powders for Additive Manufacturing

Effect of Particle Size, Lubricant, and Heat Temperature on the Flowability of Ni-Based Powders for Additive Manufacturing

Densities, Surface Tensions, and Viscosities of Molten High‐Silicon Electrical Steels with Different Silicon Contents

Density, surface tension, and viscosity of various liquid electrical steels are measured at different temperatures, varying in their silicon content between 3 and 6 mass%. Density and surface tension are determined using the maximum bubble pressure method, while viscosity is investigated comparatively using a vibrating finger viscometer and an oscillating crucible viscometer. The results are compared with models known from the literature. Based on this, the density of the steel [ρ] = kg m−3 and the surface tension [σ] = N m−1 can be described as a function of temperature [θ] = °C and silicon content [Si] = mass% using the equations: , . There is a lack of experimental data in the literature for high‐temperature thermophysical properties for electrical steels. This underlines once again the novelty and significance of this study, as the determined thermophysical properties are essential for a wide range of applications. For instance, they are crucial in the production of metallic powders for additive manufacturing by atomization to adjust the properties of the powders precisely. The findings are also important for steelmaking itself, as the corrosion behavior of refractory material can be better determined.

Preparation and characterization of nanoparticle reinforced Ti6Al4V composite powder for additive manufacturing

Preparation and characterization of nanoparticle reinforced Ti6Al4V composite powder for additive manufacturing

Spreading anomaly semantic segmentation and 3D reconstruction of binder jet additive manufacturing powder bed images

Variability in the inherently dynamic nature of additive manufacturing introduces imperfections that hinder the commercialization of new materials. Binder jetting produces ceramic and metallic parts, but low green densities and spreading anomalies reduce the predictability and processability of resulting geometries. In situ feedback presents a method for robust evaluation of spreading anomalies, reducing the number of required builds to refine processing parameters in a multivariate space. In this study, we report layer-wise powder bed semantic segmentation for the first time with a visually light ceramic powder, alumina, or Al2O3, leveraging an image analysis software to rapidly segment optical images acquired during the additive manufacturing process. Using preexisting image analysis tools allowed for rapid analysis of 316 stainless steel and alumina powders with small data sets by providing an accessible framework for implementing neural networks. Models trained on five build layers for each material to classify base powder, parts, streaking, short spreading, and bumps from recoater friction with testing categorical accuracies greater than 90%. Lower model performance accompanied the more subtle spreading features present in the white alumina compared to the darker steel. Applications of models to new builds demonstrated repeatability with the resulting models, and trends in classified pixels reflected corrections made to processing parameters. Through the development of robust analysis techniques and feedback for new materials, parameters can be corrected as builds progress.

Noncontact measurement of density and thermal properties of SS 316L powder bed through flash thermography

PurposePowder bed density is a key parameter in powder bed additive manufacturing (AM) processes but is not easily monitored. This research evaluates the possibility of non-invasively estimating the density of an AM powder bed via its thermal properties measured using flash thermography (FT).Design/methodology/approachThe thermal diffusivity and conductivity of the samples were found by fitting an analytical model to the measured surface temperature after flash of the powder on a polymer substrate, enabling the estimation of the powder bed density.FindingsFT estimated powder bed was within 8% of weight-based density measurements and the inferred thermal properties are consistent with literature findings. However, multiple flashes were necessary to ensure precise measurements due to noise in the experimental data and the similarity of thermal properties between the powder and substrate.Originality/valueThis paper emphasizes the capability of Flash Thermography (FT) for non-contact measurement of SS 316 L powder bed density, offering a pathway to in-situ monitoring for powder bed AM methods including binder jetting (BJ) and powder bed fusion. Despite the limitations of the current approach, the density knowledge and thermal properties measurements have the potential to enhance process development and thermal modeling powder bed AM processes, aiding in understanding the powder packing and thermal behavior.

Electrolyte-Plasma Production of Metal Powders for Additive Manufacturing

Electrolyte-Plasma Production of Metal Powders for Additive Manufacturing

Stereologically corrected particle size distributions for polymer-mounted additive manufacturing powders

Well-defined particle size distributions are required for good flowability and powder packing properties of additive manufacturing powders. Mounting powders within a polymer and using standard metallurgical preparation techniques to cross-section and prepare powder particles for optical analysis allows for simple characterisation processes. However, measured diameters of cross-sectioned particles are typically underestimates of actual particle diameters and hence require stereological correction. The effectiveness of three stereological corrections are investigated in this work, namely the Scheil-Schwartz-Saltykov method, the Goldsmith-Cruz-Orive method and a Finite Difference Method. These methods are investigated against plasma-atomised, gas-atomised and ultrasonically processed Ti-6Al-4V powders. The corrected outputs are compared to laser size diffraction, benchmark data for each powder. Although all three stereological corrections produce improved estimations of the particle size distributions, the Finite Difference Method is recommended producing cumulative mean absolute error values of 2.4%, 3.1% and 7.5% for the plasma-atomised, gas-atomised and ultrasonically processed powders respectively.

Wet chemical surface functionalization of AA2017 powders for additive manufacturing

Laser Powder Bed Fusion (L-PBF) is an important route for processing aluminum alloys, nevertheless, the high laser reflectivity and thermal conductivity and lower powder flowability of the aluminum alloys remain a challenge for their processing. Aiming to overcome these issues, AA2017 powders were surface-functionalized using chemical etchings. The powders' physical and rheological characterization revealed a decrease in the laser reflectance and an improvement in the flowability of the surface-functionalized powders, when compared to the gas-atomized powder. The higher amount of keyhole porosity in the as-printed L-PBF samples using the surface-functionalized powders also suggests an improvement in the laser absorption of these powders. However, the formation of a thick oxide layer on the surface-functionalized powders led to oxidation porosity in the as-printed samples. Therefore, the chemical etching should be improved to avoid the formation of a thick oxide layer on the powder surface and oxidation porosity in the as-printed L-PBF samples.

Influence of powder surface chemistry on the defect formation in AlSi10Mg alloy processed via laser powder bed fusion additive manufacturing

In laser powder bed fusion(LPBF) additive manufacturing(AM) of Al alloys, surface chemistry and dissolved gas composition(oxygen/oxides/hydroxides, hydrogen and moisture) of AM powders is a major influencing factor for porosity formation. Therefore, in the present investigation, this aspect is addressed using two sets of virgin AM AlSi10Mg powders, namely, Hi-Ox (2770 ppm oxygen) and Lo-Ox (660 ppm oxygen), to assess the printability under various processing parameters and defect formation in printed parts. Comprehensive and in-depth metallurgical analysis of both powders utilizing multiple characterisation techniques established the presence of various types of oxides/hydroxides with different complex chemistries on the powders’ surface. Enhanced spherical gas porosity and oxide inclusions were witnessed in Hi-Ox print coupons in contrast to the least defects in Lo-Ox coupons rationalized due to surface chemistry difference between the virgin powders. Consequently, the mechanical properties of the Hi-Ox print coupons, even with minimum defect density, are significantly inferior to Lo-Ox specimens. These observations suggest a competing influence of surface chemistry/dissolved gas composition and laser parameters for the processing of both powders. Overall, by correlating the microstructures with processing conditions and oxide concentration, defects morphology, the probable melt pool formation mechanism in LPBF of AlSi10Mg alloy (for high and low oxygen concentration) is elucidated.

Gas atomization of AA2017 aluminum alloy: Effect of process parameters in the physical properties of powders for additive manufacturing

Close-coupled gas atomization (CCGA) uses pressurized gas jets to atomize molten metals, producing powders suitable for additive manufacturing (AM). Optimization of processing parameters is crucial to achieve powders with good fluidity and high apparent density for laser powder bed fusion (L-PBF) and increase production yield. This study evaluated the influence of melt feed nozzle diameter, superheating temperature, and atomization pressure on AA2017 aluminum alloy powders' physical properties. Parameters variation poorly affected the median particle diameter (d50), while significantly altering the particle size distribution curves width (IDR = d90-d10). Suitable powders for AM/L-PBF were produced using a specific set of parameters (d0= 1.5 mm; ΔT= 150 °C; PG= 20 Bar), presenting appropriate fluidity and apparent density due to an optimal granulometric distribution and morphological characteristics. Mathematical analysis showed a good correlation between experimental and calculated mean particle size, suggesting an equation to predict percentile d90 based on previous correlations.

Powder characterisation and the impact on part performance in electron beam melted Ti6Al4V

Metallic powder for Additive Manufacturing (AM) typically varies between different batches, while being supplied to achieve the same customer specification. In order to reduce this variation and minimise waste, batches are often mixed together in both their virgin and used form. However, the properties of bulk components must have limited variance in order to be reliably used in an industrial setting. This manuscript is focused on the analysis of Grade 5 Ti6Al4V powders (3 virgin, plus 2 blends) and the associated mechanical properties of Electron Beam Melted (EBM) AM specimens. Measurements were performed in accordance with the principles defined in the MMPDS Handbook, ESDU database, and ASTM F2924. The tensile, and fatigue properties of the EBM specimens were found to be superior when compared with Ti6Al4V properties within these standards. This demonstrated that these powders are suitable for a wide range of commercial applications, and that these blended powders (including used powders) are able to achieve these requirements. Additionally, the results provide a systematic route for powder verification and highlight the importance of adhering to standardised principles and specifications to ensure quality and reliability in metallic AM materials.

Corrosion behaviour of Ti6Al4VxCryNi alloys fabricated by μ-plasma arc powder additive manufacturing process

This manuscript examines development of noble corrosion-resistant Ti6Al4VxCryNi alloys by μ-plasma arc powder additive manufacturing (μ-PAPAM) process for chemical, shipbuilding, and aerospace industries. Inclusion of chromium and/or nickel to Ti6Al4V alloy decreased corrosion rate and corrosion current density and increased corrosion potential and polarisation resistance, implying increased corrosion resistance. The EIS findings indicated that the values of polarization resistance and layer thickness of oxides increased with the addition of chromium and/or nickel to Ti6Al4V alloy. Smaller size pits were observed on the corroded surfaces of developed Ti6Al4VxCryNi alloys due to the formation of relatively more stable layer of Cr2O3 and NiO enabled by the inclusion of chromium and/or nickel to Ti6Al4V alloy. It improved the surface finish of the developed alloys, indicating less damage by their corrosion and the appearance of small-size pits due to layer formation of Cr2O3 and NiO. As compared to Ti6Al4V alloy, Ti6Al4V5Cr alloy has maximum corrosion resistance followed by Ti6Al4V2.5Cr2.5Ni and Ti6Al4V5Ni alloy.

New insights into the mechanism of ultrasonic atomization for the production of metal powders in additive manufacturing

Ultrasonic atomization is one of the promising technologies for producing metal powders for additive manufacturing, where precise control of particle size and morphology is essential. In this study, we coupled an ultrasonic transducer with a carbon fiber plate and atomized liquid droplets and films under different vibration amplitudes. Water, glycerol, and pure aluminum melt were used to study the atomization mechanism and the resulting droplet/powder characteristics, respectively. High-speed optical and ultrafast synchrotron X-ray imaging were used to study in situ the ultrasonic atomization dynamics, including pulsation and clustering of cavities inside the liquid layer/films, development of capillary waves, and formation of liquid droplets. For the first time, we observed and captured the occurrence of cavitation during the atomization of resting drops, films and impact droplets. The inertial cavitation events interfered with the capillary waves across the interphase boundary, puncturing and breaking the boundary to produce atomized mist. The in situ observation revealed the intricate dynamics of ultrasonic atomization and underscored the pivotal role of cavitation events throughout the entire atomization process. We also conducted experiments on ultrasonic atomization of liquid aluminum, producing particles of perfectly spherical shape. The particle size tended to decrease with reduced vibration amplitude Our work has demonstrated the important processing strategies on how to tailor the particle size while ensuring consistent particle shape and morphology, which is the key processing capability for producing high quality powders for additive manufacturing applications.

Inorganic Fullerene-Like WS2 Reinforced Polyamide Powders for Improved Mechanical Properties in Laser Sintered Nanocomposite Parts

Polyamide (PA) is a widely utilized engineering polymer, and its thermal and mechanical properties can be further improved by adding nanofillers. However, adding inorganic fullerene-like tungsten disulfide (IF-WS2) nanoparticles (NPs) to PA to produce composite precursor powders for additive manufacturing is challenging. Here, we report a novel and cost-effective method for fabricating PA-12 based nanocomposite (NC) powders with fixed/partially encapsulated IF-WS2 nanoparticulate fillers utilizing an advanced mixing technique because simple wet mixing (WM) can only attach fillers weakly to the powder surfaces when compared to the proposed method. The resulting nanocomposite powders maintained nearly the original particle size distribution of PA-12. They also exhibited improved rheological properties, melting, and crystallization behaviors compared with those prepared by the WM method. The laser-sintered PA-12 nanocomposite specimens revealed enhanced powder thermal stability and higher tensile strengths than pristine PA-12, validating the advantages of the novel technique for the fabrication of polyamide nanocomposite powders and their suitability for utilization in laser sintering additive manufacturing. These results demonstrate that high-performance engineered PA-12 nanocomposite components can be directly laser sintered, and this technique can potentially be extended to fabricate other engineered polymeric nanocomposite powders.

Assessing the mechanical properties of out-of-specification additive manufacturing Ti-6Al-4V powder recycled through field-assisted sintering technology (FAST)

A gas atomised Ti-6Al-4V powder, classified as out-of-specification for additive manufacturing (AM), was consolidated via Field-Assisted Sintering Technology (FAST). Fully dense 250 mm diameter discs with lamellar or bimodal microstructures were produced by FAST processing either above or below the β-transus temperature. Static and dynamic mechanical properties were assessed by testing full-size specimens in the ‘as-FAST’ condition. Material from both processing conditions exceeded the ASTM Ti-6Al-4V powder metallurgy requirements for yield/tensile strength and elongation. Furthermore, material from the edge of the disc processed below the β-transus temperature meets ASTM requirements for wrought Ti-6Al-4V. Fatigue performance also compared favourably with conventionally processed Ti-6Al-4V. This work establishes that surplus AM powders can be successfully recycled via the one-step FAST process and provides confidence that this ASTM-grade material can be used in a range of applications under both static and dynamic loading, which will improve the sustainability credentials of the AM sector.

Solid-state production of uniform metal powders for additive manufacturing by ultrasonic vibration machining

This work presents a new technique to generate uniform and micron-sized metal powders for additive manufacturing. By collecting discrete chips resulting from ultrasonic vibration machining, we demonstrate the feasibility of all solid-state production consistent powders with tight dimensional tolerance, the ability to control powder geometry, and good efficiency. The technique offers a new route for sustainable and low-cost manufacturing of high-quality metal powders. The powder generation mechanism is analyzed with a special tool path design to ensure consistent dimensions over multiple cuts. An analytical model to predict the dimensions of produced powders under different cutting parameters is introduced. Aluminum and brass powders of different dimensions are produced, and the overall shear ratio that governs the deformation during the machining process is calibrated with the experimental results. The morphology consistency of produced powders is investigated over multiple hours of production, illuminating the role of tool wear on final powder shape. A high-efficiency powder collection system and a scalable solution for parallel production are proposed for the introduced technique. Additive manufacturing experiments (laser powder bed fusion) are conducted using produced A356 aluminum powders, demonstrating the printability of produced powders in additive manufacturing. The microhardness of the printed parts for five different process parameters is measured to be 45% higher than the raw material on average.