Influence of particle size on powder rheology and effects on mass flow during directed energy deposition additive manufacturing

Iams, A. D.; Gao, Mingze; Shetty, Abhishek; Palmer, Todd

doi:10.1016/j.powtec.2021.10.059

Cited by 35 publications

(13 citation statements)

References 32 publications

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“…This kind of analysis gives information about the number of particles measured at each diameter [ 24 ]. Considering this, the CL31 and HM powders presented very different PSD number.…”

Section: Resultsmentioning

confidence: 99%

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Evaluation of a Laboratory-Scale Gas-Atomized AlSi10Mg Powder and a Commercial-Grade Counterpart for Laser Powder Bed Fusion Processing

et al. 2022

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Laser powder bed fusion (LPBF) is an additive manufacturing technology that implies using metal powder as a raw material. The powders suitable for this kind of technology must respect some specific characteristics. Controlled gas atomization and post-processing operations can strongly affect the final properties of the powders, and, as a consequence, the characteristics of the bulk components. In fact, a complete characterization of the powders is mandatory to fully determine their properties. Beyond the most used tests, such as the volume particle size distribution (PSD) and flowability, the PSD number, the Hausner ratio and the oxidation level can give additional information otherwise not detectable. The present work concerns the complete characterization of two AlSi10Mg powders: a commercial-grade gas atomized powder and a laboratory-scale gas atomized counterpart. The laboratory-scale gas atomization allows to better manage the amount of the fine particles and the oxidation level. As a consequence, a higher particle packing can be reached with an increase in the final density and tensile strength of the LPBF bulk samples.

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“…This kind of analysis gives information about the number of particles measured at each diameter [ 24 ]. Considering this, the CL31 and HM powders presented very different PSD number.…”

Section: Resultsmentioning

confidence: 99%

“…This kind of analysis is a measure of the space occupied by the particles, with a specific size. For this reason, the presence of finer particles is highlighted less effectively [ 24 ]. In fact, contrary to the PSD number, the PSD volume of the CL31 and HM ( Figure 3 a) are similar.…”

Section: Resultsmentioning

confidence: 99%

Evaluation of a Laboratory-Scale Gas-Atomized AlSi10Mg Powder and a Commercial-Grade Counterpart for Laser Powder Bed Fusion Processing

et al. 2022

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“…Satellites and internal pores during the AM process are also inherited in deposited material from gas-atomized powders that lead to reduction of the mechanical properties. In addition, some studies have shown that an increase in the number of satellites can affect the behavior of particles in the gas flow, which also leads to the formation of porosity in the metal [10].…”

Section: Gas Atomization (Ga)mentioning

confidence: 99%

Features of the Powder Application in Direct Laser Deposition Technology

Gushchina¹,

Klimova-Korsmik²,

Turichin³

2023

New Advances in Powder Technology

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The chapter presents the basic aspects of the use of metal powders in one of the main additive technologies—direct laser deposition (DLD). Direct laser deposition refers to a group of direct energy deposition (DED) methods and is analogous to Laser Metal Deposition (LMD) technology. The main requirements applied to DLD used metal powders are analyzed and substantiated. The influence of the basic properties of the powders on the quality of the deposited samples is demonstrated. An example of incoming quality control of powders, allowing its application in DLD technology, is presented. The results of experimental research on obtaining quality control samples for the most used metallic materials are presented. The results of structure and properties studies for the main groups of alloys based on iron, nickel, and titanium are shown. The potential for manufacturing products for various areas of industry using DLD has been demonstrated.

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“…Recent rheological measurements of soils in areas that experience debris flows show a transition from rate-independent behaviour to fluid-like behaviour (Kostynick et al 2022), similar to that found in the current experiments. The current results are also relevant to the rheological modelling of flows that combine fluidization and shear, such as in the feeding of additive manufacturing powders (Iams et al 2022), in flow enhancement of sand for mould and coremaking processes (Bakhtiyarov, Overfelt & Siginerm 2002), handling of fine cohesive powders (Mishra et al 2020(Mishra et al , 2022, aeration effects in vibratory powder conveyer (Hartig et al 2022) and in clinical grade manufacturing of 3D printed devices in personalized medicine (Ramaraju et al 2022).…”

Section: Introductionmentioning

confidence: 95%

Flow transitions and effective properties in multiphase Taylor–Couette flow

Young,

Shetty,

Hunt

2024

J. Fluid Mech.

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The properties of multiphase flows are challenging to measure, and yet effective properties are fundamental to modelling and predicting flow behaviour. The current study is motivated by rheometric measurements of a gas-fluidized bed using a coaxial rheometer in which the fluidization rate and the rotational speed can be varied independently. The measured torque displays a range of rheological states: quasistatic, dense granular flow behaviour at low fluidization rates and low-to-moderate shear rates; turbulent toroidal-vortex flow at high shear rates and moderate-to-high fluidization rates; and viscous-like behaviour with rate-dependent torque at high shear rates and low fluidization or at low shear rates and high fluidization. To understand the solid-like to fluid-like transitions, additional experiments were performed in the same rheometer using single-phase liquid and liquid–solid suspensions. The fluidized bed experiments are modelled as a Bingham plastic for low fluidization rates, and as a shear-thinning Carreau liquid at high fluidization rates. The suspensions are modelled using the Krieger–Dougherty effective viscosity. The results demonstrate that, by using the effective properties, the inverse Bingham number marks the transition from solid-like to viscous-flow behaviour; a modified gap Reynolds number based on the thickness of the shear layer specifies the transition from solid-like to turbulent vortical flow; and a gap Reynolds number distinguishes viscous behaviour from turbulent vortical flow. The results further demonstrate that these different multiphase flows undergo analogous flow transitions at similar Bingham or Reynolds numbers and the corresponding dimensionless torques show comparable scaling in response to annular shear.

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Influence of particle size on powder rheology and effects on mass flow during directed energy deposition additive manufacturing

Cited by 35 publications

References 32 publications

Evaluation of a Laboratory-Scale Gas-Atomized AlSi10Mg Powder and a Commercial-Grade Counterpart for Laser Powder Bed Fusion Processing

Evaluation of a Laboratory-Scale Gas-Atomized AlSi10Mg Powder and a Commercial-Grade Counterpart for Laser Powder Bed Fusion Processing

Features of the Powder Application in Direct Laser Deposition Technology

Flow transitions and effective properties in multiphase Taylor–Couette flow

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