Impact of IN718 bimodal powder size distribution on the performance and productivity of laser powder bed fusion additive manufacturing process

Farzadfar, S. A.; Murtagh, Martin J.; Venugopal, Navin

doi:10.1016/j.powtec.2020.07.092

Cited by 30 publications

(15 citation statements)

References 4 publications

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“…The high density of the powder layer can provide faster production of parts without compromising their quality [ 20 ]. The use of powder alloy IN718 containing 83.75 vol.% fine fraction (D 10 –D 90 : 6.2–16.9 µm), and 16.25 vol.% coarse fraction (D 10 –D 90 : 26.5–50.5) when manufacturing parts by typical laser powder bed fusion resulted in a 10% increase in process productivity, higher tensile strength, and reduced mechanical anisotropy [ 21 ]. Additionally, the higher the layer density, the lower the surface roughness [ 22 ].…”

Section: Introductionmentioning

confidence: 99%

Preparation of Nano/Micro Bimodal Aluminum Powder by Electrical Explosion of Wires

et al. 2021

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Electrical explosion of aluminum wires has been shown to be a versatile method for the preparation of bimodal nano/micro powders. The energy input into the wire has been found to determine the relative content of fine and coarse particles in bimodal aluminum powders. The use of aluminum bimodal powders has been shown to be promising for the development of high flowability feedstocks for metal injection molding and material extrusion additive manufacturing.

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Section: Introductionmentioning

confidence: 99%

Preparation of Nano/Micro Bimodal Aluminum Powder by Electrical Explosion of Wires

et al. 2021

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“…[52][53][54] Finer particles generally fill the void between relatively larger particles and thus result in a higher packing density which affects the spread. 48,55 As discussed by Kishimoto et al, Fe-Cr-Ti powders mechanically alloyed with Y 2 O 3 to produce 14YWT exhibit irregular, 'asteroid' shaped morphology. 56 The AM literature has predominantly focused on LPBF of MA compositions like PM2000, 10 MA956, 11 and other Fe-Cr-W-Ti compositions mechanically alloyed with Y 2 O 3 .…”

Section: Powder Characterizationmentioning

confidence: 99%

“…The gauge crosssection of the coupons was 3.18 mm 9 3.18 mm, and the gauge length was 9.53 mm with a 12.7-mm radius fillet. The specimens were subjected to uniaxial loading in tension at room temperature based on ASTM E8/E8M standard on an ATS model 1620C by Applied Test Systems Inc. with a crosshead speed of 0.1 mm/s 47,48 and a 5-kN autocorrected load cell. Digital image correlation (DIC) was performed to map surface displacement fields during testing and calculate strain 49 using GOM Correlate (2021 Hotfix 3, Rev 144,264).…”

Section: Characterization Of Lpbf Consolidated 14ywtmentioning

confidence: 99%

Laser Powder Bed Fusion of ODS 14YWT from Gas Atomization Reaction Synthesis Precursor Powders

Saptarshi

deJong

Rock

et al. 2022

JOM

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Laser powder bed fusion (LPBF) additive manufacturing (AM) is a promising route for the fabrication of oxide dispersion strengthened (ODS) steels. In this study, 14YWT ferritic steel powders were produced by gas atomization reaction synthesis (GARS). The rapid solidification resulted in the formation of stable, Y-containing intermetallic Y2Fe17 on the interior of the powder and a stable Cr-rich oxide surface. The GARS powders were consolidated with LPBF. Process parameter maps identified a stable process window resulting in a relative density of 99.8%. Transmission electron microscopy and high-energy x-ray diffraction demonstrated that during LPBF, the stable phases in the powder dissociated in the liquid melt pool and reacted to form a high density (1.7 × 1020/m3) of homogeneously distributed Ti2Y2O7 pyrochlore dispersoids ranging from 17 to 57 nm. The use of GARS powder bypasses the mechanical alloying step typically required to produce ODS feedstock. Preliminary mechanical tests demonstrated an ultimate tensile and yield strength of 474 MPa and 312 MPa, respectively.

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“…It is also shown that the average particle size of the Cu powder is 40.0 µm which is larger than that of the CoCrFeNi and Ti powders. There has been some limited research completed into AM of powders of different particle size distributions where smaller particles were interstitial between larger particles resulting in a higher packing density and a more homogeneous part [48]. However, the particle size difference in this case is not enough for the CoCrFeNi to be interstitial in the packing of the larger Cu particles, therefore it is assumed that both powder mixes will result in comparable packing densities.…”

Section: Powder Analysismentioning

confidence: 99%

In-Situ Alloying of CoCrFeNiX High Entropy Alloys by Selective Laser Melting

Farquhar

Maddison

Hardwick

et al. 2022

Metals

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High Entropy Alloys are a class of alloys which have been shown to largely exhibit stable microstructures, as well as frequently good mechanical properties, particularly when manufactured by additive manufacturing. Due to the large number of potential compositions that their multi-component nature introduces, high throughput alloy development methods are desirable to speed up the investigation of novel alloys. Here, we explore once such method, in-situ alloying during Additive Manufacture, where a powder of a certain pre-alloyed composition is mixed with the required composition of powder of an additional element, such that alloying takes place when powders are melted during the process. To test the effectiveness and capability of the approach, selective laser melting has been used to manufacture pre-alloyed CoCrFeNi, and also CoCrFeNiCu and CoCrFeNiTi alloys by combining pre-alloyed CoCrFeNi powder with elemental powders of Cu and Ti. Processing parameter variations are used to find the highest relative density for each alloy, and samples were then characterised for microstructure and phase composition. The CoCrFeNi alloy shows a single phase face centred cubic (FCC) microstructure, as found with other processing methods. The CoCrFeNiCu alloy has a two phase FCC microstructure with clear partitioning of the Cu, while the CoCrFeNiTi alloy has an FCC matrix phase with NiTi intermetallics and a hexagonal close packed (HCP) phase, as well as unmelted Ti particles. The microstructures therefore differ from those observed in the same alloys manufactured by other methods, mainly due to the presence of areas with higher concentrations than usually encountered of Cu and Ti respectively. Successful in-situ alloying in this process seems to be improved by the added elemental powder having a lower melting point than the base alloy, as well as a low inherent tendency to segregate. While not producing directly comparable microstructures however, the approach does seem to offer advantages for the rapid screening of alloys for AM processability, identifying, for example, extensive solid-state cracking in the CoCrFeNiTi alloy.

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Impact of IN718 bimodal powder size distribution on the performance and productivity of laser powder bed fusion additive manufacturing process

Cited by 30 publications

References 4 publications

Preparation of Nano/Micro Bimodal Aluminum Powder by Electrical Explosion of Wires

Preparation of Nano/Micro Bimodal Aluminum Powder by Electrical Explosion of Wires

Laser Powder Bed Fusion of ODS 14YWT from Gas Atomization Reaction Synthesis Precursor Powders

In-Situ Alloying of CoCrFeNiX High Entropy Alloys by Selective Laser Melting

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