Characterizing the Effect of Thermal Processing on Feedstock Al Alloy Powder for Additive Manufacturing Applications

Walde, Caitlin; Cote, Danielle L.; Champagne, Victor K.; Sisson, Richard D.

doi:10.1007/s11665-018-3550-0

Cited by 33 publications

(34 citation statements)

References 7 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…8). The decreased proportion of precipitates that can be observed in the particles cross-section ( Fig.3) was recently quantified as a function of heat treatment time [40]. It was confirmed that a thermal processing was reducing the quantity of the majority of the precipitates that can be found in as-atomised particles.…”

Section: Discussionmentioning

confidence: 56%

Inter-particle bonding in cold spray deposition of a gas-atomised and a solution heat-treated Al 6061 powder

Sabard

Hussain

2019

J Mater Sci

View full text Add to dashboard Cite

The heat-treatment of a number of gas atomised aluminium alloys prior to cold spraying recently showed that the resultant microstructural modification was accompanied by an improvement in deposition; however, the relationship between the microstructural homogenisation occurring after recrystallisation and the increase in deposition efficiency and particle-particle bonding had not been investigated. In this study, Al 6061 gas atomised feedstock powder, before and after solution heattreatment, was cold sprayed and these materials were characterised using electron backscatter diffraction. The solution heat-treated Al 6061 powder showed large stress-free grains as opposed to the as-atomised feedstock powder which exhibited smaller grains with the presence of dislocations. The coating produced from as-received powder exhibited a homogeneous distribution of misorientation and lattice defects throughout the particles, whereas the coating produced from solution heat-treated powder showed an accumulation of dislocations in the interfacial zones. For the first time, a mechanism was proposed where this phenomenon was attributed to localised deformation of the heat-treated particle's exterior due to the dissolution of precipitates in the intermetallic network. The accumulation of dislocations in the interfacial area enhanced the rotation of subgrains to accommodate the plastic deformation, thus improving the particle-particle bonding.

show abstract

Section: Discussionmentioning

confidence: 56%

Inter-particle bonding in cold spray deposition of a gas-atomised and a solution heat-treated Al 6061 powder

Sabard

Hussain

2019

J Mater Sci

View full text Add to dashboard Cite

show abstract

“…Additionally, it was recently noted that these gas-atomized powders have both granular and subgranular features. The secondary phases exist at all boundaries, with groups of subgrains having the same orientation, comprising larger grains [4,5,15]. The size of the substructure is typically what is reported for these powders; when etched, it is impossible to distinguish between the high-angle and low-angle boundaries that differentiate the grains and subgrains.…”

Section: Introductionmentioning

confidence: 99%

“…For example, Rokni et al [3] showed that the feedstock powder microstructure is retained in cold spray deposits. With this in mind, it is important to understand the microstructure of the powders prior to consolidation [4,5].…”

Section: Introductionmentioning

confidence: 99%

“…The feedstock powders are often gas-atomized, experiencing cooling rates on the order of 10 6 °C/s during solidification [6]. This categorizes the powders as rapidly solidified, which results in microstructures very different than conventional castings, where the cooling rate is on the order of less than 10 2 °C/s [5]. Minimal segregation, nonequilibrium phases, and microstructure homogeneity are characteristics of rapidly solidified structures [6][7][8].…”

Section: Introductionmentioning

confidence: 99%

“…Solutionization times for Al 7075 are typically on the order of 4-16 h for wrought components, depending on part size [9]. Given this timescale, other researchers chose to use long heat treatment times for their powders; however, other researches performed on Al 6061 indicated faster diffusion times in powders, resulting in the need for shorter thermal treatments [5,10].…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Phase Transformations in Thermally Treated Gas-Atomized Al 7075 Powder

Walde

Tsaknopoulos

Champagne

et al. 2020

Metallogr. Microstruct. Anal.

Self Cite

View full text Add to dashboard Cite

Al 7075 is a heat-treatable Al-Mg-Zn alloy widely used in the aerospace industry. Recently, it has found application as feedstock for metal additive manufacturing (MAM). It has been shown that wrought alloy compositions in powder form differ in microstructure and properties from their conventional form. Given this, it is important to understand the microstructure of the powders prior to use in MAM processes. This work studies as-atomized gas-atomized Al 7075 powders and the effect of thermal treatments on microstructure. Extensive electron microscopy revealed the presence of T-phase, Al 7 Cu 2 Fe, and Mg 2 Si in the as-atomized condition. Thermal treatments were performed at 465 °C and 480 °C to homogenize the microstructure; however, S-phase was unexpectedly present in the samples treated at 465 °C. In both 465 °C and 480 °C treatments, T-phase was not fully dissolved after the 60-min treatment. Guided by thermodynamic modeling, these results indicate a shift in local equilibria in these powders.

show abstract

Metal Additive Manufacturing: Materials, Methods, Microstructure Evolution and Mechanical Properties via Post-processing Heat Treatments

Mohamed

Kaviarasu²,

Danielwillson

et al. 2022

Materials Horizons: From Nature to Nanomaterials

View full text Add to dashboard Cite

Characterizing the Effect of Thermal Processing on Feedstock Al Alloy Powder for Additive Manufacturing Applications

Cited by 33 publications

References 7 publications

Inter-particle bonding in cold spray deposition of a gas-atomised and a solution heat-treated Al 6061 powder

Inter-particle bonding in cold spray deposition of a gas-atomised and a solution heat-treated Al 6061 powder

Phase Transformations in Thermally Treated Gas-Atomized Al 7075 Powder

Metal Additive Manufacturing: Materials, Methods, Microstructure Evolution and Mechanical Properties via Post-processing Heat Treatments

Contact Info

Product

Resources

About