A comparative study of water and gas atomized low alloy steel powders for additive manufacturing

Fedina, Tatiana; Sundqvist, Jesper; Powell, John; Kaplan, Alexander

doi:10.1016/j.addma.2020.101675

Cited by 36 publications

(19 citation statements)

References 25 publications

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“…La forma de estas partículas es característica de polvos metálicos obtenidos por procesos de atomización con gas, los cuales se producen por efecto de la dispersión de material fundido provocada por la inyección de gas a través de una boquilla, la cual rompe el líquido fundido en pequeñas gotas. Las partículas fundidas generadas por efecto del atomizado se enfrían rápidamente durante su caída sobre un depósito para posteriormente ser recolectadas [24]. micrómetros de diámetro, con un rango entre 5 y 100 micrómetros en su distribución total.…”

Section: Resultados Y Análisisunclassified

Fusión Láser en Cama De Polvos De Un Vidrio Metálico Base Hierro: Estudio Exploratorio

Penenrey

2022

rev. colom. mater.

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Actualmente, la fabricación de componentes volumétricos a partir de vidrios metálicos y/o aleaciones fuera del equilibrio es un reto debido a las condiciones de enfriamiento requeridas para obtener un estado amorfo completo y/o un conjunto de fases en particular. Algunas tecnologías de fabricación aditiva, como la sinterización directa de metal por láser (DMLS), pueden ofrecer una alternativa para la fabricación de componentes de vidrio metálico a partir de polvos de materia prima 100 % amorfos. El principal desafío cuando estos materiales se procesan mediante fabricación aditiva es mantener el contenido amorfo del polvo inicial en las piezas finales. En el presente trabajo, se empleó un vidrio metálico comercial con hierro como su elemento principal, con el fin de realizar un estudio exploratorio de la influencia de los principales parámetros del proceso DMLS sobre la capacidad de este material para formar piezas consolidadas por este proceso. Los parámetros estudiados aquí fueron la potencia del láser, la velocidad de escaneo y la densidad de energía volumétrica. Se empleó la técnica de difracción de rayos X para realizar la caracterización de las fases obtenidas en las piezas fabricadas. Los resultados del estudio sugieren que la fabricación de piezas con el material estudiado es posible, pero existe un rango de densidades de energía aplicadas por el láser durante el proceso dentro de los que se favorece la formación de las piezas.

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Section: Resultados Y Análisisunclassified

Fusión Láser en Cama De Polvos De Un Vidrio Metálico Base Hierro: Estudio Exploratorio

Penenrey

2022

rev. colom. mater.

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“…They found differences in the as-built microstructure that warrant different heat treatment schedules. Several studies on the PBF-LB of AISI 4130 low alloy steel powder prepared by WA have been conducted [7,8]. These demonstrate the feasibility of AM processing of WA powder.…”

Section: Introductionmentioning

confidence: 89%

Electron Beam Powder Bed Fusion of Water Atomized Iron and Powder Blends

et al. 2022

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In the present state of the art, highly spherical alloy powders are employed as feedstock in powder bed fusion processes. These powders are characterized by high flowability and apparent density. Their elaborate fabrication process is reflected in high powder price, adding a significant fraction to the cost of additively manufactured parts. Thus, the use of non-spherical powders, such as water atomized material, can lower costs significantly. Here, the electron beam powder bed fusion (PBF-EB) of standard water atomized iron powder used for press-and-sinter is studied. Despite raking problems, using the coating mechanism in standard configuration samples with densities exceeding 99% were fabricated. In a further step, the addition of alloying elements by powder blending is explored. Important powder properties of feedstock blended from irregular and spherical powders are characterized. The PBF-EB processing of two alloys is presented. The first represents a low carbon steel. Samples were characterized by metallographic cross-section, energy dispersive X-ray (EDX) mapping, and mechanical testing. The second alloy system is a FeCrAl. After PBF-EB processing of the powder mixture, chemical homogeneity was achieved. Besides the low cost, this approach of using water atomized powder mixed with master alloy offers the advantage of high flexibility for potential application.

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“…While gas atomized metal powders are standard in PBF-AM, there has been growing interest in finding ways of using low 'spreadability' water atomized metal powders owing to their significantly lower cost [20][21][22][23][24]. It has been shown to be possible to use water atomized metallic powders in selective laser powder bed melting [21,22,25], though reports of success remain relatively few. No published results for water atomized powder used in selective electron beam melting have been reported to our knowledge.…”

Section: Introductionmentioning

confidence: 99%

Vibratory Powder Feeding for Powder Bed Additive Manufacturing Using Water and Gas Atomized Metal Powders

Sinclair

Edinger²,

Sparling

et al. 2021

Materials

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Commercial powder bed fusion additive manufacturing systems use re-coaters for the layer-by-layer distribution of powder. Despite the known limitations of re-coaters, there has been relatively little work presented on the possible benefits of alternative powder delivery systems. Here, we reveal a feeding technology that uses vibration to control flow for powder bed additive manufacturing. The capabilities of this approach are illustrated experimentally using two very different powders; a ‘conventional’ gas atomized Ti-6Al-4V powder designed for electron beam additive manufacturing and a water atomized Fe-4 wt.% Ni alloy used in powder metallurgy. Single layer melt trials are shown for the water atomized powder to illustrate the fidelity of the melt tracks in this material. Discrete element modelling is next used to reveal the mechanisms that underpin the observed dependence of feed rate on feeder process parameters and to investigate the potential strengths and limitations of this feeding methodology.

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A comparative study of water and gas atomized low alloy steel powders for additive manufacturing

Cited by 36 publications

References 25 publications

Fusión Láser en Cama De Polvos De Un Vidrio Metálico Base Hierro: Estudio Exploratorio

Fusión Láser en Cama De Polvos De Un Vidrio Metálico Base Hierro: Estudio Exploratorio

Electron Beam Powder Bed Fusion of Water Atomized Iron and Powder Blends

Vibratory Powder Feeding for Powder Bed Additive Manufacturing Using Water and Gas Atomized Metal Powders

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