Article
Materials Science, Multidisciplinary
Sebastien Germain Careau, Elena Ulate-Kolitsky, Alexandre Bois-Brochu
Summary: This study demonstrates the feasibility of using the electrode induction gas atomization process (EIGA) to produce spherical Ti-5Fe powder for additive manufacturing. The resulting powder is spherical and defect-free. The distribution of iron throughout the microstructure is homogeneous and shows similar particle size distribution and oxygen pick-up as the conventional Ti-6Al-4V titanium alloy, proving that Ti-5Fe can achieve comparable atomization behavior and powder quality. The results of this study highlight the efficient scale-up potential of EIGA-type gas atomization for producing low-cost Ti-5Fe titanium alloy powder for additive manufacturing, expanding the possibilities for biomaterial applications.
Article
Engineering, Manufacturing
Thomas Achee, Gabe Guss, Alaa Elwany, Manyalibo Matthews
Summary: The study shows that the laser pre-sintering (LPS) method is most effective in the 1-4 J/mm(3) volumetric energy density processing regimes, minimizing the common experimentally observed problems with the LPBF process.
ADDITIVE MANUFACTURING
(2021)
Article
Chemistry, Physical
M. A. Ackers, O. M. D. M. Messe, N. Manninen, O. Stryzhyboroda, U. Hecht
Summary: This study aimed to develop a novel titanium alloy for medical applications using additive manufacturing technology as an alternative to traditional Ti-6Al-4V alloy, with performance evaluation and research on related properties.
JOURNAL OF ALLOYS AND COMPOUNDS
(2022)
Article
Materials Science, Multidisciplinary
Zhiqiang Ren, Sheng Zhu, Xiaoming Wang, Yang Zhao, Guofeng Han, Kebing Zhou, Wenyu Wang, Gen Tian
Summary: AlCrCoNiCu high-entropy alloy powder was prepared by gas atomization method, with spherical shape, homogeneous composition, and face-center cubic phase (FCC). Addition of Fe and Mn elements resulted in the appearance of both FCC and body-center cubic phase (BCC), with a particle size mainly ranging from 10 to 50 micrometers. The smaller the particle size, the more regular the shape and the lower the surface roughness. This study provided an experimental and theoretical reference for preparing high-performance single-phase and multi-phase high entropy alloy spherical powders.
Article
Chemistry, Physical
Krzysztof Grzelak, Marcin Bielecki, Janusz Kluczynski, Ireneusz Szachogluchowicz, Lucjan Sniezek, Janusz Torzewski, Jakub Luszczek, Lukasz Sloboda, Marcin Wachowski, Zenon Komorek, Marcin Malek, Justyna Zygmuntowicz
Summary: The significant growth of Additive Manufacturing has resulted in increased demand for small gradation metallic powders. This study compares powders obtained through ultrasonic atomization and gas atomization methods, analyzing their particle distribution, chemical composition, density, and flowability. Test samples created using both methods were analyzed for differences in microstructure, porosity, and hardness. Mechanical properties were also analyzed through tensile testing and impact tests. The study confirms that both methods can deliver materials with similar properties.
Article
Engineering, Chemical
Yufan Zhao, Yujie Cui, Yusaku Hasebe, Huakang Bian, Kenta Yamanaka, Kenta Aoyagi, Takehito Hagisawa, Akihiko Chiba
Summary: Powder flowability plays a crucial role in additive manufacturing, influenced by particle size distribution, particle morphology, and surface features. Experimental evaluation and numerical simulations on Inconel 718 alloy powders revealed that PREP powder exhibited the best flowability due to high particle sphericity and thin surface oxide film. Control of environmental factors during handling can lead to a natural advantage of PREP over GA and PA in terms of flowability.
Article
Chemistry, Physical
Kuaikuai Guo, Changsheng Liu, Wei Chen, Chang Luo, Jianzhong Li
Summary: This study utilizes the Electrode Induction Melting Gas Atomization (EIGA) technology to produce metal powders and simulates the primary disintegration process of molten metal using Computational Fluid Dynamics (CFD) approach. The results show that high-speed spraying and recirculation are the main areas for atomization, and increasing gas pressure leads to smaller particle size and narrower size distribution.
Article
Engineering, Manufacturing
Rahul Davis, Abhishek Singh, Kishore Debnath, Roberta Maia Sabino, Ketul Popat, Paulo Soares, Anup Kumar Keshri, Bhaskar Borgohain
Summary: In the field of high-precision miniaturized medical implants, the biomedical Ti-6Al-4V alloy meets the requirements for longevity, biocompatibility, and sterilizability. By adding different concentrations of bioactive zinc powder particles, the researchers were able to reduce machining time and dimensional deviation in micro-electric discharge machining. The combination of a copper micro-tool electrode and a 6 g/l zinc powder concentration showed the best results, with lower machining time, dimensional deviation, and recast layer thickness. The modified alloy surface also showed potential for dental applications and potential antiviral activity against COVID-19.
JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME
(2022)
Article
Metallurgy & Metallurgical Engineering
Emre Yurtkuran, Rahmi Unal
Summary: This study investigated the potential of producing titanium alloy metal powder using low-power plasma torches. By designing an argon DC non-transferred arc plasma torch and conducting numerical analysis, the properties of the plasma jet and wire temperature were determined. The study found that spherical powders could be successfully produced using relatively low torch power.
TRANSACTIONS OF NONFERROUS METALS SOCIETY OF CHINA
(2022)
Article
Chemistry, Physical
Cekdar Vakifahmetoglu, Beyza Hasdemir, Lisa Biasetto
Summary: This paper investigates the spreadability of spherical CoCrWMo powder for laser-powder bed fusion and examines its relationship with powder characteristics. The results demonstrate that an increase in fine particle ratio leads to agglomeration and decreases flowability, resulting in poor spreadability.
Article
Materials Science, Multidisciplinary
Erika Soares Barreto, Maximilian Frey, Jan Wegner, Allen Jose, Nico Neuber, Ralf Busch, Stefan Kleszczynski, Lutz Maedler, Volker Uhlenwinkel
Summary: This study systematically investigated the application of Cu-Ti-Zr-Ni family (Vitreloy 101) in PBF-LB/M powder processing. Gas atomization was used to produce Vitreloy 101 and its derivatives micro-alloyed with Si and Sn. The influence of atomization and alloy composition on powder properties was studied. The results showed that high-purity amorphous powder with good flowability and particle morphology can be obtained by controlling the surface-to-volume ratio of the powder.
MATERIALS & DESIGN
(2022)
Article
Materials Science, Multidisciplinary
Sheng Luo, Hongze Wang, Zhenyang Gao, Yi Wu, Haowei Wang
Summary: Simulation of the gas atomization process reveals that different types of metal powders are formed due to the Kelvin-Helmholtz instability and droplet breakup and closure phenomena. Suggestions for reducing defects have been proposed based on the revealed mechanisms.
MATERIALS & DESIGN
(2021)
Article
Nanoscience & Nanotechnology
Z. Liu, T. Chen, W. S. Cai, H. Z. Lu, Z. C. Lu, D. Wang, X. Q. Li, X. Y. Zhang, C. Yang
Summary: In this study, a discharge plasma modification method is used to treat recycled titanium powder, resulting in the production of high-performance titanium alloy materials. This provides an inexpensive and sustainable approach for manufacturing high-performance metallic components via laser powder bed fusion.
SCRIPTA MATERIALIA
(2023)
Article
Materials Science, Multidisciplinary
Liu Yingjie, Hu Qiang, Zhao Xinming, Wang Zhigang, Zhang Shaoming, Wang Yonghui, Zhang Jinhui
Summary: An experimental device for centrifugal atomization of rotating disk was developed independently, producing high fluidity aluminum alloy powder for additive manufacturing. The properties of the powder show high fluidity, narrow size distribution, good sphericity, and smooth surface, resulting in 3D printed parts with more uniform laser cladding coating and less hole defects. The mechanical properties of the parts are significantly better than those produced by gas atomization.
RARE METAL MATERIALS AND ENGINEERING
(2021)
Article
Materials Science, Multidisciplinary
Avinash Hariharan, Phil Goldberg, Tobias Gustmann, Emad Maawad, Stefan Pilz, Frederic Schell, Tim Kunze, Christoph Zwahr, Annett Gebert
Summary: This study investigates the additive manufacturing of near beta-type Ti-13Nb-13Zr alloys using the LPBF process and explores the optimization of process parameters and post-processing strategies. The research achieves stable process and high part density, and demonstrates excellent mechanical and corrosion properties. The findings are of great significance for the development of personalized orthopedic implants.
MATERIALS & DESIGN
(2022)
Article
Materials Science, Multidisciplinary
R. P. Turner, M. Villa, Y. Sovani, C. Panwisawas, B. Perumal, R. M. Ward, J. W. Brooks, H. C. Basoalto
METALLURGICAL AND MATERIALS TRANSACTIONS B-PROCESS METALLURGY AND MATERIALS PROCESSING SCIENCE
(2016)
Article
Materials Science, Multidisciplinary
Richard P. Turner, Chinnapat Panwisawas, Yogesh Sovani, Bama Perumal, R. Mark Ward, Jeffery W. Brooks, Hector C. Basoalto
METALLURGICAL AND MATERIALS TRANSACTIONS B-PROCESS METALLURGY AND MATERIALS PROCESSING SCIENCE
(2016)
Article
Engineering, Manufacturing
R. P. Turner, D. Howe, B. Thota, R. M. Ward, H. C. Basoalto, J. W. Brooks
JOURNAL OF MANUFACTURING PROCESSES
(2016)
Article
Materials Science, Multidisciplinary
P. Bidare, I. Bitharas, R. M. Ward, M. M. Attallah, A. J. Moore
Article
Engineering, Manufacturing
P. Bidare, I Bitharas, R. M. Ward, M. M. Attallah, A. J. Moore
INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE
(2018)
Article
Automation & Control Systems
P. Bidare, I. Bitharas, R. M. Ward, M. M. Attallah, A. J. Moore
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2018)
Article
Materials Science, Multidisciplinary
R. P. Turner, B. Perumal, Y. Lu, R. M. Ward, H. C. Basoalto, J. W. Brooks
METALLURGICAL AND MATERIALS TRANSACTIONS B-PROCESS METALLURGY AND MATERIALS PROCESSING SCIENCE
(2019)
Article
Materials Science, Multidisciplinary
M. Villa, J. W. Brooks, R. P. Turner, H. Wang, F. Boitout, R. M. Ward
METALLURGICAL AND MATERIALS TRANSACTIONS B-PROCESS METALLURGY AND MATERIALS PROCESSING SCIENCE
(2019)
Article
Materials Science, Multidisciplinary
Chuan Guo, Zhengrong Yu, Chang Liu, Xinggang Li, Qiang Zhu, R. Mark Ward
Article
Engineering, Industrial
Chuan Guo, Zhen Xu, Yang Zhou, Shi Shi, Gan Li, Hongxing Lu, Qiang Zhu, R. Mark Ward
Summary: Single-track experiments were conducted using nickel-based superalloy IN738LC to investigate the effects of processing parameters on track morphology and bead features during laser powder bed fusion. It was found that the stability of the track and bead mode could be influenced by the processing parameters in certain conditions. Additionally, under specific circumstances, the solidification of droplets could result in instability of the track.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2021)
Article
Materials Science, Multidisciplinary
Matteo Villa, Jeffery W. Brooks, Richard Turner, Frederic Boitout, Robin Mark Ward
Summary: This study examined the microstructure evolution of Ti-6Al-4V titanium alloy during high energy density welding process through numerical simulations and experimental validations. The numerical predictions were shown to reasonably match with experimental results, validating various metallurgical features of the alloy.
Article
Engineering, Multidisciplinary
Chuan Guo, Zhengrong Yu, Xiaogang Hu, Gan Li, Fan Zhou, Zhen Xu, Shuang Han, Yang Zhou, R. Mark Ward, Qiang Zhu
Summary: In this study, an in-situ Y2O3 nanoparticles decorated Inconel 738 LC composite was fabricated, significantly enlarging the process window and eliminating cracks in the printed parts. Additionally, Zr enrichment in Y4Al2O9 particles was observed, effectively inhibiting Zr segregation along grain boundaries. After heat treatment, the particle size doubled, resulting in improved strength of the material.
COMPOSITES PART B-ENGINEERING
(2022)
Article
Materials Science, Multidisciplinary
Chuan Guo, Yang Zhou, Xinggang Li, Xiaogang Hu, Zhen Xu, Enjie Dong, Qiang Zhu, R. Mark Ward
Summary: The study compared the effects of continuous-wave and pulsed-wave laser beam modes on the fabrication of Inconel 738 LC samples, finding that pulsed wave could effectively eliminate cracks and improve the mechanical performance of the parts. The refinement of grains and higher cooling rate under the pulsed-wave laser beam were found to be key factors in crack elimination. Parts fabricated under the pulsed-wave mode exhibited superior mechanical performance compared to those under the continuous-wave mode.
JOURNAL OF MATERIALS SCIENCE & TECHNOLOGY
(2021)
Article
Engineering, Industrial
Chuan Guo, Sheng Li, Shi Shi, Xinggang Li, Xiaogang Hu, Qiang Zhu, R. Mark Ward
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2020)
Article
Materials Science, Multidisciplinary
Chinnapat Panwisawas, Bama Perumal, R. Mark Ward, Nathanael Turner, Richard P. Turner, Jeffery W. Brooks, Hector C. Basoalto
