A comparative study of Ti-6Al-4V powders for additive manufacturing by gas atomization, plasma rotating electrode process and plasma atomization

Chen, G.; Zhao, S.Y.; Pan, Tan; Wang, Jian; Xiang, Chang Shu; Tang, Huiping

doi:10.1016/j.powtec.2018.04.013

Cited by 207 publications

(83 citation statements)

References 32 publications

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“…When characterising a powder, it is important that the following three main parts are included: particle morphology, particle chemistry and particle microstructure. [198][199][200][201] Currently, research is primarily focused on the morphological characterisation of powders and their effect on the properties of fabricated parts. The properties of the final consolidated components, such as the mechanical and anti-corrosive properties, may also be influenced by whether the feedstock powders are argon-or nitrogen-atomised and whether the build chambers are argon-or nitrogen-purged.…”

Section: Discussionmentioning

confidence: 99%

Corrosion of metallic materials fabricated by selective laser melting

Kong

2019

npj Mater Degrad

186

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Additive manufacturing is an emerging technology that challenges traditional manufacturing methods. However, the corrosion behaviour of additively manufactured parts must be considered if additive techniques are to find widespread application. In this paper, we review relationships between the unique microstructures and the corresponding corrosion behaviour of several metallic alloys fabricated by selective laser melting, one of the most popular powder-bed additive technologies for metals and alloys. Common issues related to corrosion in selective laser melted parts, such as pores, molten pool boundaries, surface roughness and anisotropy, are discussed. Widely printed alloys, including Ti-based, Al-based and Fe-based alloys, are selected to illustrate these relationships, and the corrosion properties of alloys produced by selective laser melting are summarised and compared to their conventionally processed counterparts.

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Section: Discussionmentioning

confidence: 99%

Corrosion of metallic materials fabricated by selective laser melting

Kong

2019

npj Mater Degrad

186

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“…The quality and properties of the feedstock materials depend a lot on the manufacturing process, which, in the case of metal powders for LPBF, can be quite varied [18,[62][63][64][65][66][67], ranging from rotary, water, and gas atomization [66][67][68][69][70] to the plasma rotating electrode process (PREP) [71,72]. Furthermore, in order to make the additive manufacturing process more cost-efficient and to reduce the price of the feedstock, the reuse of scraps and chips produced by traditional manufacturing of expensive metals and alloys (i.e., Ti-6Al-4V, aluminum) was proposed via spheroidization [73,74] and milling [75,76].…”

Section: Powder Feedstock Featuresmentioning

confidence: 99%

Material Reuse in Laser Powder Bed Fusion: Side Effects of the Laser—Metal Powder Interaction

Santecchia

Spigarelli

Cabibbo

2020

Metals

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Metal additive manufacturing is changing the way in which engineers and designers model the production of three-dimensional (3D) objects, with rapid growth seen in recent years. Laser powder bed fusion (LPBF) is the most used metal additive manufacturing technique, and it is based on the efficient interaction between a high-energy laser and a metal powder feedstock. To make LPBF more cost-efficient and environmentally friendly, it is of paramount importance to recycle (reuse) the unfused powder from a build job. However, since the laser-powder interaction involves complex physics phenomena and generates by-products which might affect the integrity of the feedstock and the final build part, a better understanding of the overall process should be attained. The present review paper is focused on the clarification of the interaction between laser and metal powder, with a strong focus on its side effects. Figure 1. Schematics of the laser powder bed fusion (LPBF) equipment. Adapted from Reference [9] with permission from Elsevier.While the market and the applications of laser powder bed fusion continuously and impressively grew in recent years, there is a common view across users and researchers concerning the repeatability of the process in terms of chemical composition and mechanical properties of the final parts, which are of paramount importance when challenging environmental or testing conditions are considered [10][11][12][13][14][15][16].The most typical approach to study the microstructural and mechanical properties of parts built by LPBF is to compare them with castings of the same alloy or, rather, the corresponding alloy since the starting material is metal powder rather than a fuse. However, in some existing alloys designed for cast and wrought parts, laser additive manufacturing processing results in cracking or other microstructure deficiencies [11,12,16,17]. It is worth noting that LPBF has more similarities with laser welding rather than casting, since the two laser-based techniques have some common features (i.e., melt-pool formation, moving heat source) [18]. However, process parameters are, in general, quite different in terms of laser power and scan speed, and the laser-matter interaction is much more complicated in LPBF processes, since the powder feedstock is inherently unstable and the solidified material undergoes multiple thermal cycles corresponding to the fusion of subsequent layers during the additive process [19][20][21][22]. Furthermore, owing to the similarities with welding and to the complicated interaction between laser and metal particles, when comparing laser powder bed fusion with other metal forming processes, it is evident that the range of processable alloys is very limited and the number of high-productivity commercially available alloys is even smaller [23]. One of the reasons behind this is that the level of metal powder sensitivity to the laser action during LPBF is not yet fully understood, despite the efforts of the scientific community to uncover it [24][25][26][27], and ...

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“…Chen at el. [20] have shown that porosity in powder particles can depend on the method of powder production as well as on the particle size. Also, the distribution of particles in the powder bed may lead to additional component porosity due to voids between particles.…”

Section: Introductionmentioning

confidence: 99%

3D Shape Analysis of Powder for Laser Beam Melting by Synchrotron X-ray CT

Thiede

Mishurova

Evsevleev

et al. 2019

QuBS

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The quality of components made by laser beam melting (LBM) additive manufacturing is naturally influenced by the quality of the powder bed. A packing density <1 and porosity inside the powder particles lead to intrinsic voids in the powder bed. Since the packing density is determined by the particle size and shape distribution, the determination of these properties is of significant interest to assess the printing process. In this work, the size and shape distribution, the amount of the particle’s intrinsic porosity, as well as the packing density of micrometric powder used for LBM, have been investigated by means of synchrotron X-ray computed tomography (CT). Two different powder batches were investigated: Ti–6Al–4V produced by plasma atomization and stainless steel 316L produced by gas atomization. Plasma atomization particles were observed to be more spherical in terms of the mean anisotropy compared to particles produced by gas atomization. The two kinds of particles were comparable in size according to the equivalent diameter. The packing density was lower (i.e., the powder bed contained more voids in between particles) for the Ti–6Al–4V particles. The comparison of the tomographic results with laser diffraction, as another particle size measurement technique, proved to be in agreement.

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A comparative study of Ti-6Al-4V powders for additive manufacturing by gas atomization, plasma rotating electrode process and plasma atomization

Cited by 207 publications

References 32 publications

Corrosion of metallic materials fabricated by selective laser melting

Corrosion of metallic materials fabricated by selective laser melting

Material Reuse in Laser Powder Bed Fusion: Side Effects of the Laser—Metal Powder Interaction

3D Shape Analysis of Powder for Laser Beam Melting by Synchrotron X-ray CT

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