Surface inoculation of aluminium powders for additive manufacturing of Al-7075 alloys

Vieth, Pascal; Voigt, Markus; Ebbert, Christoph; Milkereit, Benjamin; Zhuravlev, Evgeny; Yang, Bin; Keßler, Olaf; Grundmeier, Guido

doi:10.1016/j.procir.2020.09.004

Cited by 5 publications

(5 citation statements)

References 19 publications

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“…An analogous behavior was reported for Al-Si-Mg-Ti powder dry coated with TiC (Xinwei et al, 2020). Also wet coating of Al7075 (Vieth et al, 2020) and AlSi10Mg (Wang and Shi, 2020) with TiC nanoparticles by means of ultrasonication and wet ball milling was shown to be a feasible functionalization approach, although this process route has the drawback to demand for an additional drying step and potential contamination or oxidation of the alloy. Also for parts manufactured from Al6061/TiC composite powder prepared by planetary ball milling, a reduction of cracks was observed (Qu et al, 2022).…”

Section: Aluminum Alloy Feedstock Powderssupporting

confidence: 59%

Dry powder coating in additive manufacturing

Schmidt

Peukert

2022

Front. Chem. Eng.

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Dry powder coating is used in many industries to tailor the bulk solid characteristics of cohesive powders. Within this paper, the state of the art of dry coating of feedstock materials for powder based additive manufacturing (AM) processes will be reviewed. The focus is on feedstock materials for powder bed fusion AM processes, such as powder bed fusion of polymers with a laser beam and powder bed fusion of metals with lasers or an electron beam. Powders of several microns to several ten microns in size are used and the feedstock’s bulk solid properties, especially the flowability and packing density are of immanent importance in different process steps in particular for powder dosing and spreading of powder layers onto the building area. All these properties can be tuned by dry particle coating. Moreover, possibilities to improve AM processability and to manipulate the resulting microstructure (c.f. grain refinement, dispersion strengthening) by adhering nanoparticles on the powders will be discussed. The effect of dry coating on the obtained powder properties along the whole AM process chain and the resulting part properties is assessed. Moreover, appropriate characterization methods for bulk solid properties of dry-coated AM powders are critically discussed.

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Section: Aluminum Alloy Feedstock Powderssupporting

confidence: 59%

Dry powder coating in additive manufacturing

Schmidt

Peukert

2022

Front. Chem. Eng.

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“…Supporting colloidal NPs requires a wet coating technique followed by additional drying [27]. Fluidized bed drying is a suitable method where the powders can be wet mixed and dried in the same unit with a relatively short processing time, facilitating minimum cross-contamination [26,40].…”

Section: Additivation Processmentioning

confidence: 99%

“…Depending on the material types, powder feedstocks have different melting and crystallization temperatures during the heating and cooling stages of PBF-LB. These temperatures can be shifted by introducing NPs [27,28,38]. Metal powders entirely melt during the PBF-LB process.…”

Section: Thermal Behaviormentioning

confidence: 99%

“…However, there are different cooling rates throughout the powder bed volume, which is difficult to mimic for DSC. A new approach of differential fast scanning calorimetry (DFSC) with very rapid heating and cooling rates can represent the PBF-LB process conditions better, to understand the rapid heating and cooling behavior of metal and polymer powder feedstocks [27,28,62]. Derived from DSC and DFCS, a total of 120 data points for metals and 120 data points for polymers will be generated by measuring the melting and crystallization temperature of the metal and polymer powders (Figure 4).…”

Section: Thermal Behaviormentioning

confidence: 99%

“…Furthermore, some metal alloy elements can be vaporized during laser melting that affects the solidification microstructure and part quality [43]. As discussed above (Section 2.2.1), XRF [27,33,40] and/or ICP-OES [36] will measure the as-built polymer and metal parts' chemical composition. Measurements by XRF have to be carried out on the polished surface of metal and polymer cubes.…”

Section: Chemical Compositionmentioning

confidence: 99%

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Nanoparticle Additivation Effects on Laser Powder Bed Fusion of Metals and Polymers—A Theoretical Concept for an Inter-Laboratory Study Design All Along the Process Chain, Including Research Data Management

et al. 2021

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In recent years, the application field of laser powder bed fusion of metals and polymers extends through an increasing variability of powder compositions in the market. New powder formulations such as nanoparticle (NP) additivated powder feedstocks are available today. Interestingly, they behave differently along with the entire laser powder bed fusion (PBF-LB) process chain, from flowability over absorbance and microstructure formation to processability and final part properties. Recent studies show that supporting NPs on metal and polymer powder feedstocks enhances processability, avoids crack formation, refines grain size, increases functionality, and improves as-built part properties. Although several inter-laboratory studies (ILSs) on metal and polymer PBF-LB exist, they mainly focus on mechanical properties and primarily ignore nano-additivated feedstocks or standardized assessment of powder feedstock properties. However, those studies must obtain reliable data to validate each property metric’s repeatability and reproducibility limits related to the PBF-LB process chain. We herein propose the design of a large-scale ILS to quantify the effect of nanoparticle additivation on powder characteristics, process behavior, microstructure, and part properties in PBF-LB. Besides the work and sample flow to organize the ILS, the test methods to measure the NP-additivated metal and polymer powder feedstock properties and resulting part properties are defined. A research data management (RDM) plan is designed to extract scientific results from the vast amount of material, process, and part data. The RDM focuses not only on the repeatability and reproducibility of a metric but also on the FAIR principle to include findable, accessible, interoperable, and reusable data/meta-data in additive manufacturing. The proposed ILS design gives access to principal component analysis (PCA) to compute the correlations between the material–process–microstructure–part properties.

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