Powder Deposition Research Articles

Effect of plasma spray FeCrAly coating on microstructural and mechanical properties of Ni61Cr22Mo9Fe5 - ER2209 nickel based alloy fabricated using wire arc additive manufacturing process

In this current research, the Ni61Cr22Mo9Fe5 (NiCr) - ER2209 (FeCr) wire was proposed to produce a nickel based alloy materials utilising the wire arc additive manufacturing (WAAM) process. Wire arc additive manufacturing (WAAM) and wire arc additive manufacturing coated (WAAM-C) samples of two different types were created. In order to improve the WAAM sample's mechanical strength and corrosion resistance, the outer surface layer was coated using the plasma spray FeCrAlY composite coating technique. The deposition of powder was kept as constant as 200 µm during plasma spray coating process. Microstructure analyses showed that the composite bonding sample had NiFe2O4, Single phase nickel ferrite (SPNF), Ni-Co ferrite, α-phase, and Spinel ferrite structures. The metallic functional phase (MFP) of Ni61Cr22Mo9Fe5 - ER2209 wire was shaped utilizing additive manufacturing process, whilst homogeneous structure and NiCr structure were established collateral bonding in the base materials. Texture results of WAAM-C sample showed As1 < 111 > , As2 < 200 >, As3 < 211 > and As4 < 222 > cub structure at the outer surface. The hardness values of outer surface layers of WAAM-C have been continuously increased by 4 % compared to the WAAM sample. The hardness values of WAAM-C and WAAM were seen as 180 HV and 166 HV, respectively. The WAAM-C showed the elongation of 3 % and yield strength of 600 MPa. Further, the fracture morphology revealed that both the samples did not show dimples, void, crack and hole. WAAM-C materials achieved higher corrosion resistance and good surface finish. Further, potential dynamic investigations were conducted on both WAAM and WAAM-C samples.

Deposition and characterization of plasma sprayed NiTi powder on stainless steel and graphite substrate

The surface behavior of the NiTi coating has been studied by composition analysis, microstructure, and interface diffusion. The shape memory effect was investigated by thermal recovery of the indented surface at various loads. Near the theoretical density (99.3%), high Vickers hardness 244–310 HV, was measured by applying various loads of 1961–98 mN for NiTi samples separated from graphite substrate. However, samples prepared from stainless steel substrate display more homogenous hardness at various loads from 214 to 238 HV with applied load from 98 to 490 mN. Phase transformation temperatures indicated that above 105 °C, the alloy transforms and is saturated in the austenite stage. Both samples exhibited a hysteresis effect of shape memory effect on bending mode in thermal cycles. Both samples were indented at various loads from 98 to 1961 mN load for 10 s, and residual indent points are imaged. Recovery in the depth of indent points was analyzed after heating samples above austenite finish temperature at 150 °C for 10 min. A maximum recovery of 77% is achieved in the sample retrieved from stainless steel substrate at 245 mN load.

Visualization of nasal powder distribution using biomimetic human nasal cavity model

Nasal drug delivery efficiency is highly dependent on the position in which the drug is deposited in the nasal cavity. However, no reliable method is currently available to assess its impact on delivery performance. In this study, a biomimetic nasal model based on three-dimensional (3D) reconstruction and three-dimensional printing (3DP) technology was developed for visualizing the deposition of drug powders in the nasal cavity. The results showed significant differences in cavity area and volume and powder distribution in the anterior part of the biomimetic nasal model of Chinese males and females. The nasal cavity model was modified with dimethicone and validated to be suitable for the deposition test. The experimental device produced the most satisfactory results with five spray times. Furthermore, particle sizes and spray angles were found to significantly affect the experimental device's performance and alter drug distribution, respectively. Additionally, mometasone furoate (MF) nasal spray (NS) distribution patterns were investigated in a goat nasal cavity model and three male goat noses, confirming the in vitro and in vivo correlation. In conclusion, the developed human nasal structure biomimetic device has the potential to be a valuable tool for assessing nasal drug delivery system deposition and distribution.

Cold spraying of Al-aerospace alloys: Ease of coating deposition at high stagnation temperatures

Cold spray is the only solid-state coating technique to deposit thick metallic coatings. Deposition of metallic and metallic alloy powders is carried out at the temperature lower than the melting point. Since spraying of Al-based aerospace alloys are associated with nozzle clogging, successful deposition is restricted to nitrogen or helium as the main process gas with a polymer nozzle. Deposition of the alloys using air as process gas at elevated stagnation temperatures (up to 600 °C) has benefits in the repair and refurbishment sector, especially in aerospace. In this study, the effect of elevated stagnation temperatures (from 400 to 600 °C) using air as the main process gas on the deposition characteristics of aerospace grade Al-alloys (Cp-Al, Al-2024, Al-6061 and Al-7075) is studied. Deposition of the alloys at various stagnation temperatures is studied using FEM and correlated with the coating thickness. The deposition behaviour is studied using various parameters such as lattice misfit calculations and solid solution strengthening calculations. The ease of cold spray deposition of Al-aerospace alloys is systematically studied and listed as Al-6061 > Cp-Al > Al-7075 > Al-2024 for the first time.

A novel triple-cathode plasma torch with hot-wall nozzle for YSZ spherical thin-walled hollow-shell powder preparation

Yttria-stabilized zirconia spherical thin-walled hollow-shell powder (YSZ-STHS) is a highly promising ceramic top-coat materials used in thermal barrier coatings with good homogeneity, a low thickness and no continuous flaws. However, the current technologies for preparing yttria-stabilized zirconia hollow spherical powder (YSZ-HOSP), such as spray drying, inductively coupled plasma spheroidization, and arc plasma spheroidization, face challenges in producing YSZ-STHS due to thick shell thickness and low hollow powder ratio. The triple-cathode plasma torch (TCPT) has characteristics such as high enthalpy and axial powder feeding, making it a promising tool for YSZ-STHS preparation. However, the plasma torch nozzle is often clogged due to powder deposition on the cold anode wall, limiting its application. To address this issue, a novel spheroidization method using a TCPT with hot-wall nozzle is proposed to achieve low shell thickness and high hollow powder ratio in YSZ-STHS powder preparation. Experiments were carried out to investigate the electro-thermal characteristics of the TCPT. The results indicated that the TCPT displayed a high mean enthalpy ranging from 2.37×107 J/kg to 3.36×107 J/kg and a low arc voltage fluctuation of ±1 V, indicating that the proposed TCPT is capable of producing a stable plasma jet with a high temperature. Additionally, experiments and numerical simulations were conducted to reveal the effect of the hot-wall nozzle. The results revealed that the hot-wall nozzle increased the inner wall temperature, decreased the radial temperature gradient of the plasma jet, reduced the nozzle clogging, and extends the high-temperature region and maximum temperature inside the nozzle. Finally, YSZ-STHS preparation by TCPT with hot-wall nozzle was demonstrated through experiments. The results showed that YSZ-STHS with a high spheroidization ratio close to 100%, a high hollow powder ratio of 93.4%, a thin shell thickness with an average value of 3.63 μm, and fully tetragonal phase was successfully prepared, demonstrating the effectiveness of the proposed TCPT with hot-wall nozzle for the preparation of YSZ-STHS.

Development and Evaluation of Multiscale Fiber-reinforced Composite Powders for Powder-bed Fusion Process

The development of multiscale fiber-reinforced composite powders is an effective way to improve the mechanical properties and functionality of additively manufactured parts. Herein, a novel thermally induced precipitation process is proposed for preparing multiscale fiber-reinforced powders. A systematic evaluation was conducted to explore the main factors influencing powder morphology, powder flow, and microstructure. In the powder-forming mechanism, the polymer matrix is coated on the microfiber, and a film of carbon nanotubes covers the powder surface, which is promoted by heterogeneous nucleation. The composite powders comprised polyamide 12, carbon fiber (CF), and carbon nanotubes, which have been successfully applied in powder bed fusion processes including selective laser sintering (SLS). Smooth flow and powder deposition were observed, and the composite components obtained via SLS were well-fabricated using the optimized process parameters. A CF loading ratio of up to 66.7 wt% and homogeneous fiber distribution within the matrix were successfully achieved.

Microstructure evolution and tribological properties of (TiB+TiC)/Ti–6Al–4V composites fabricated via in situ laser-directed energy deposition of wire and powders in an underwater environment

Titanium-matrix composite-reinforced restored layers are used to repair cracks and dents on titanium alloy shells to impart the deposition layer with the same properties as the base metal. However, there are few studies on their underwater applications. Underwater laser-directed energy deposition is a rapidly-developing technique that shows great application potential for underwater restoration projects. This paper reports the effect of the Ti/(B+C) ratio on the microstructure and mechanical properties of a layer restored underwater using CWPLDED. The results showed that the ceramic-reinforced phase transitioned from a quasi-continuous mesh distribution to a multi-point distribution as the Ti/(B+C) ratio changed. The matrix grain was refined because the reinforcing phase promoted the non-spontaneous nucleation of β-Ti and α-Ti and limited grain growth during both solidification and solid-state phase transformation. The composite layer restored underwater had a maximum ultimate tensile strength of 1231.18 ± 6.37 MPa and a maximum yield strength of 1158.11 ± 8.71 MPa. When Ti: B: C = 3: 4: 4, the improved wear resistance of the restored layer was attributed to the higher microhardness caused by an increased precipitated phase content and Ti matrix grain refinement. When Ti: B: C = 3: 4: 1, the restored layer exhibited better wear resistance due to the excellent spatial configuration of the reinforced phase. The intrinsic relationship between the (B+C) content, reinforced phase space, and dry sliding wear performance was revealed. This provides a design window for preparing (TiB+TiC)/Ti64 composite restored layers with excellent comprehensive performance by CWPLDED and offers new insights for repairing titanium alloys underwater.

Model of the Selective Laser Melting Process-Powder Deposition Models in Multistage Multi-Material Simulations

This paper presents one of the final stages in the development of a holistic model of the selective laser melting (SLM) process. The holistic model developed previously allows for modeling of only one stage of SLM, which limits simulations to one cycle with one material. The lattice Boltzmann method is applied for simulation of laser treatment, melting, fluid flow, and solidification. Several models of powder bed generation were developed within the framework of the holistic model and are described in this paper. They were developed on the basis of static and dynamic physical principles with the use of cellular automata, their own code, and the Unity® platform. They employed continuous and discrete particle representation and incorporated a model of powder deposition with particles of atomized or arbitrary shape. The closing of the external simulation circuit, which contains the powder bed generation model, cycle initialization, its realization by the model based on the Lattice Boltzmann Method (LBM), and the powder removal model, allows us to finish one simulation cycle of laser treatment and initialize the next, thereby enabling multistage multi-material simulations. The simulation results of the multistage SLM process with the Ti-6Al-V alloy and bioactive glass are presented in this paper. These simulation results confirm the possibility of modeling several SLM stages with two different materials. The holistic model can be used for simulation, design, and optimization of multistage, multi-material SLM processes.

Electrical Conductivity of Pipeline Deposits Under Pressure and Their Impacts on Sales-Gas Pipeline Cathodic Protection Systems

Summary Natural gas pipelines are critical for safe and efficient energy transport across large distances. To maintain operational safety, pipelines use cathodic protection systems that minimize the rate of external corrosion. This work characterizes the effects of black powder deposits, a widely experienced operational hazard across the natural gas industry, on the failure of pipeline cathodic protection systems due to electrical “shorting” of isolation devices. Black powder sludgy deposits from coal seam gas (CSG) pipelines were analyzed, revealing electrical conductivity values within the range of 580 to 5400 µS/cm when under pipeline pressure. These values were used to calculate the internal resistances of monolithic isolation joints (MIJs), a type of electrical isolation device, to show that electrical shorting (internal resistance of &amp;lt; 100 Ω) can occur for black powder sludgy deposit thicknesses in the range of millimeters. To reduce the frequency of such shorting events, it is recommended that upstream dehydration systems be designed to reduce carry-over of triethylene glycol (TEG), that internal nonconductive coatings be applied to isolation devices, and that these devices are installed in ways that facilitate regular cleaning.

Parametric optimization in co-axial laser powder deposition of cobalt-base alloys on DIN 1.2714 die steel

In this work, cobalt-based powders (Stellite 6 and Stellite 12) were deposited on the hot forging die steel (DIN 1.2714) by direct laser deposition using a 2 kW Yb-fiber laser. Single tracks were developed by varying process parameters—powder mass flow rate (25–35 g/min), laser power (800–1100 W), and scan speed (400–800 mm/min). Further, the influence of these process parameters on clad geometry and dilution rate was studied. Optimization of parameters was carried out using grey analysis, and the results were analyzed based on analysis of variance (ANOVA). It was observed that the optimal parameters for Stellite 6 cladding are a powder mass flow rate of 25 g/min, laser power of 1100 W, and a scan speed of 400 mm/min. In contrast, the optimal parameters for Stellite 12 are a powder mass flow rate of 35 g/min, laser power of 1100 W, and a scan speed of 800 mm/min. In addition, a correlation between input and output parameters was established using regression analysis. The micrographs of the single-track cladding developed under optimal parametric conditions consist of fine cellular structure at the clad-surface interface followed by course cellular dendrites and fine equiaxed grains at the surface of the cladding. Stellite 12 cladding exhibits higher hardness (545 ± 10 HV0.3) than Stellite 6 cladding (470 ± 10 HV0.3) due to the formation of more refined grains.

Impact of spray angle and particle velocity in cold sprayed IN718 coatings

Cold spray (CS) deposition has potential applications in repair technology or additive manufacturing due to its ability to operate at low temperatures, achieve high deposition rates, and produce thick, dense coatings. For adoption of CS in repair applications, it is crucial to evaluate the influence of spray angles since geometry of repair zones are typically complex and non-flat. In this work, we investigated the influence of spray angles and particle velocities on the cold spray deposition of Inconel 718 (IN718) powder particles using N2 as propellant gas. Three oblique spray angles including 50, 60 and 70° were compared with the 90° normal spray angle for cold spray deposition of IN718 powders on Al6061 substrate. Three sets of cold spray parameters at each spray angle, giving particle velocities from 820 to 920 m/s were employed to study their effect on the coating properties. Particle velocity was found to have greater impact on coating porosity compared to spray angle. Coating with lowest porosity and lowest surface roughness but highest compressive surface residual stress was achieved with deposition at lowest spray angle (50°) and highest particle velocity (920 m/s). Changing the spray angle has greater influence on the deposition efficiency, with thickest coating observed at normal spray angle of 90° across all three cold spray conditions. Finite element method (FEM) simulations were also performed to understand the influence of powder and substrate temperatures on critical angles for bonding. The simulation results suggest that elevating the powder temperature is likely to cause a slight increase in the critical bonding angle.

Prototype Design for Grading Structures in Powder Bed Fusion Processes.

While targeted alignment in certain additive manufacturing (AM) methods such as material extrusion (MEX) and stereolithography (SLA) has been well documented in the research community, a method for targeted alignment of added fillers or fibrous materials in powder bed fusion (PBF) AM devices has yet to be successfully achieved. Similarly, incorporation of multimaterials does not work easily with any of the AM technologies. This study creates a prototype design that could be integrated into a PBF system to allow for multimaterial layer deposition and alignment of powders and powder blends. The rheological properties of polyamide powder and a range of polyamide composite blends (incorporating milled carbon fibre, graphite flakes, polytetrafluoroethylene, and glass microspheres) in different concentrations were studied, and together with the particle size distribution and particle morphology analysis were applied for the design of a prototype hopper for incorporation in the PBF system to create targeted multimaterial deposition. Different concept designs, multichambered and multi-hopper with hopper angles calculated specifically for the composite blend powders selected, were proposed. Initial deposition trials outside a PBF process were tested, and the deposited layers were measured.

Mechanical properties of the laser powder deposition and laser powder bed fusion printed 316L

Metal 3D printing technologies have made it possible to produce different parts, but the mechanical properties of the parts connected using different 3D printing technologies have not yet been sufficiently studied. In the study, 316L stainless steel was laser powder deposited (DED) with laser cladding head on the laser powder bed fusion (PBF-LB) printed 316L and the joint was investigated experimentally. The microstructure of the joint was examined from the cross-sections of the joint by optical microscopy. The mechanical properties of the joint were evaluated by hardness measurements and tensile strength tests. The microstructure of the deposited structure was similar to the typical 316L printed structure, but at the joint, due to the higher heat input of the DED process, an increase in grain size was clearly visible. Based on the hardness measurements, the hardness profile of the joint was very even, and the average hardness was approximately 305 HV. The tensile strength of the PBF-LB and DED joint was 549 MPa which is approximately 11% lower than the tensile strength of PBF-LB printed 316L.

Cold Spray metal powder deposition with 9 %Cr-steel applied for the HCPB First Wall fabrication: Proof of concept and options for ODS steel processing

At the KIT a hybrid manufacturing concept for nuclear fusion First Walls is developed combining aspects of conventional and Additive Manufacturing (AM) technologies. The state of the art for ITER does not cover all specifications of a DEMO relevant First Wall. Thus, additional R&D-work has been initiated in terms of manufacturing. The AM technology basis used in the presented process combination is Cold Spray metal powder deposition applied in alternation with machining including the feature of filling grooves temporarily with a water-soluble granulate for creation of closed channels and cavities. Thus, the technology provides the option to manufacture shells with a thin gas tight membrane on top of previously machined structures. This membrane is used as pressure seal and makes the joining of shells by Hot Isostatic Pressing (HIP) into one monolithic body possible. This paper describes the manufacturing process and recalls differences and common aspects with regard to conventional concepts of First Wall manufacturing. The achievement of Technology Readiness Level TRL 3 by mechanical qualification and comparison of the results to other HIP joint experiments is also demonstrated. Finally, an outlook is given concerning integration options of the technology into manufacturing of shells with cooling channel structures using Oxide Dispersion Strengthened (ODS) materials.

Effects of the mouthpiece and chamber of Turbuhaler® on the aerosolization of API-only powder formulations

Powder dispersion in dry powder inhalers (DPIs) is affected by powder formulations as well as the design of a device. This paper conducted a numerical investigation based on the coupled computational fluid dynamics (CFD) and discrete element method (DEM) to evaluate the changes of the design of a commercial DPI device Turbuhaler® on the aerosolization of an API-only formulation. Six different designs were proposed by modifying the mouthpiece and chamber of the original geometry which was reconstructed from a CT-scan of the Turbuhaler, and their performances in terms of powder deposition in the device and fine powder fraction (FPF) were evaluated. The resistance of the device was observed to vary with different designs. For the change of the mouthpiece, the device with a cylindrical mouthpiece had the least resistance and the lowest FPF emitted among all the devices, confirming the important role of the spiral mouthpiece on powder dispersion. Reducing the mouthpiece size caused more powder deposition in the inhaler due to higher airflow velocity, but FPF emitted increased compared to the original design as more powder dispersion occurred inside the mouthpiece. The half-length mouthpiece design reduced device resistance to increase airflow velocity and average collision energy, resulting in an increase in FPF loaded but a decrease in the number of collisions. For the change of the chamber, the domed chamber design increased the powder dispersion time and thus enhanced the frequency and energy of particle collisions, which eventually led to an increase in FPF loaded. At fixed flow rates, the powder dispersion efficiency was a function of the device resistance with higher device resistance causing an increase in the FPF loaded. However, it is important for the patient’s attainable pressure drop to be considered in this context. Correlations between the aerosolization efficiency and the ratio of the average collision energy and cohesion energy were established based on model-predicted quantities.

Additive Manufacturing Technologies of High Entropy Alloys (HEA): Review and Prospects

Additive manufacturing (AM) technologies have gained considerable attention in recent years as an innovative method to produce high entropy alloy (HEA) components. The unique and excellent mechanical and environmental properties of HEAs can be used in various demanding applications, such as the aerospace and automotive industries. This review paper aims to inspect the status and prospects of research and development related to the production of HEAs by AM technologies. Several AM processes can be used to fabricate HEA components, mainly powder bed fusion (PBF), direct energy deposition (DED), material extrusion (ME), and binder jetting (BJ). PBF technologies, such as selective laser melting (SLM) and electron beam melting (EBM), have been widely used to produce HEA components with good dimensional accuracy and surface finish. DED techniques, such as blown powder deposition (BPD) and wire arc AM (WAAM), that have high deposition rates can be used to produce large, custom-made parts with relatively reduced surface finish quality. BJ and ME techniques can be used to produce green bodies that require subsequent sintering to obtain adequate density. The use of AM to produce HEA components provides the ability to make complex shapes and create composite materials with reinforced particles. However, the microstructure and mechanical properties of AM-produced HEAs can be significantly affected by the processing parameters and post-processing heat treatment, but overall, AM technology appears to be a promising approach for producing advanced HEA components with unique properties. This paper reviews the various technologies and associated aspects of AM for HEAs. The concluding remarks highlight the critical effect of the printing parameters in relation to the complex synthesis mechanism of HEA elements that is required to obtain adequate properties. In addition, the importance of using feedstock material in the form of mix elemental powder or wires rather than pre-alloyed substance is also emphasized in order that HEA components can be produced by AM processes at an affordable cost.

Microstructural characterisation and mechanical evaluation of Ti-15Mo manufactured by laser metal deposition

A bidirectional powder deposition strategy was employed to additively manufacture Ti-15Mo wt% using laser metal deposition. Phase identification, elemental analysis and microstructural characterisation were conducted after fabrication and uniaxial tensile testing using X-ray diffraction and scanning electron microscopy along the different processing directions. In addition, electron backscattering diffraction and transmission electron microscopy were used to analyse deformation mechanisms. It was found that three distinct zones, namely the fusion, remelted and heat affected zones, evolved in all 25 deposited layers which predominantly comprised coarse columnar grains. Mo segregation was pronounced in the as-built microstructure. Deformation accommodation in β matrix was by a combination of slip, {332}<113> and {112}<111> twinning, and α′′ martensite and ωD formation contrarily to the expected twinning.

Effect of interlayer time interval on residual stress distribution in Ti6Al4V alloy manufactured by laser powder bed fusion

A finite element is developed to study the transient temperature fields and mechanical response during laser powder bed fusion processing and multi-layer deposition of a Ti6Al4V powder. Two different powder deposition time intervals are examined. The results of our analysis reveal that short-time interlayer intervals lead to a reduction of residual von Mises stress in the produced part. A good correspondence between the experimental and numerical results was found.

In vitro Evaluation of Paliperidone Palmitate Loaded Cubosomes Effective for Nasal-to-Brain Delivery.

This work aimed to develop chitosan-coated cubosomal nanoparticles intended for nose-to-brain delivery of paliperidone palmitate. They were compared with standard and cationic cubosomal nanoparticles. This comparison relies on numerous classical in vitro tests and powder deposition within a 3D-printed nasal cast. Cubosomal nanoparticles were prepared by a Bottom-up method followed by a spray drying process. We evaluated their particle size, polydispersity index, zeta-potential, encapsulation efficiency, drug loading, mucoaffinity properties and morphology. The RPMI 2650 cell line was used to assess the cytotoxicity and cellular permeation. An in vitro deposition test within a nasal cast completed these measurements. The selected chitosan-coated cubosomal nanoparticles loaded with paliperidone palmitate had a size of 305.7 ± 22.54 nm, their polydispersity index was 0.166 ± 0.022 and their zeta potential was +42.4 ± 0.2 mV. This formulation had a drug loading of 70% and an encapsulation efficiency of 99.7 ± 0.1%. Its affinity with mucins was characterized by a ΔZP of 20.93 ± 0.31. Its apparent permeability coefficient thought the RPMI 2650 cell line was 3.00E-05 ± 0.24E-05 cm/s. After instillation in a 3D-printed nasal cast, the fraction of the injected powder deposited in the olfactory region reached 51.47 ± 9.30% in the right nostril and 41.20 ± 4.59% in the left nostril, respectively. The chitosan coated cubosomal formulation seems to be the most promising formulation for nose-to-brain delivery. Indeed, it has a high mucoaffinity and a significantly higher apparent permeability coefficient than the two other formulations. Finally, it reaches well the olfactory region.

Feasibility study of AZ31B deposition made by novel powder bed friction stir process with optimal process parameters and tool features selection

The current work focused on the feasibility study of an in-house developed process at a laboratory scale named Powder Bed Friction Stir (PBFS) for AZ31B powder deposition. It employs friction stirring as a heating source instead of a laser or electron beam, as in powder bed fusion which can potentially mitigate the issues arising from liquid-solid phase transformation. A suitable process parameter and tool design was chosen through experimentation. Two sets of process parameters were selected for rotational and translational motion as 1200 rpm & 900 rpm and 360 mm/min & 200 mm/min, respectively. The material deposition is affected by tool design, so five different tools were explored. The overall height of the successful deposition was 7 mm with process parameters 1200 rpm & 360 mm/min, and (Circular Protruded Feature) CPFII tool in total 35 passes keeping layer thickness (0.2 mm). Microstructure and phase analysis were carried out using (Scanning Electron Microscopy) SEM and (X-ray Diffraction) XRD, respectively, to study the grain refinement, presence of (Inter Metallic Compounds) IMCs, and participation of the slip system in the deformation process. The resulting grain refinement was 78%, with increased basal plane intensity in the deposit. The current study offered an extension of solid-state additive manufacturing as PBFS for Mg alloys.