Characterization of Thermally Treated Gas-Atomized Al 5056 Powder

Abstract

Aluminum 5056 is a work-hardenable alloy known for its corrosion resistance with new applications in additive manufacturing. A good understanding of the secondary phases in Al 5056 powders is important for understanding the properties of the final parts. In this study, the effects of different thermal treatments on the microstructure of Al 5056 powder were studied. Thermodynamic models were used to guide the interpretation of the microstructure as a function of thermal treatment, providing insight into the stability of different possible phases present in the alloy. Through the use of transmission electron microscopy (TEM) and energy-dispersive X-ray spectroscopy (EDS), combined with thermodynamic modeling, a greater understanding of the internal microstructure of Al 5056 powder has been achieved in both the as-atomized and thermally treated conditions. Evidence of natural aging within these powders was observed, which speaks to the shelf-life of these powders and the importance of proper treatment and storage to maintain consistent results.

Evolution of Fe-Rich Phases in Thermally Processed Aluminum 6061 Powders for AM Applications

“…Additionally, the small grain size of the powders, originating from their rapid solidification, decreases diffusion distance and therefore times, greatly accelerating diffusional processes. This becomes especially important to consider when optimizing thermal processing parameters for powders [ 18 , 19 , 20 ].…”

Novel Characterization Techniques for Additive Manufacturing Powder Feedstock

“…Cano et al recently used powder properties as part of a comprehensive study on cold spray with optimization software [28]. Cote et al recently performed extensive characterization of gas-atomized Al 5056 powders, showing that the powder had been experiencing aging effects [29]. The same group also examined using machine learning to examine powder flowability, and found an accuracy of 98.04% [30].…”