A review on ICP powder plasma spheroidization process parameters

Sehhat, M. Hossein; Chandler, Jackson; Yates, Zane

doi:10.1016/j.ijrmhm.2021.105764

Cited by 25 publications

(11 citation statements)

References 70 publications

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“…These processes may pose negative effects on powder characteristics (like low chemical purity), have a limited functionality only for a speci c range of powder size, or be ine cient from an economic viewpoint. As summarized in a comprehensive review paper by Sehhat et al [20], a novel method for creating spherical powder is plasma spheroidization [21,22], which outperforms other methods by yielding a higher amount of spherical powder at a lower price and less chemical impurity. The plasma high temperatures melt powder particles and reshape them to spheres using the surface tensions as they are falling under gravity in the spheroidization machine's reactor chamber [23].…”

Section: Introductionmentioning

confidence: 99%

Numerical Study and Experimental Validation of Copper Powder Plasma Spheroidization Process

Sehhat

Leu²

2023

Preprint

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As the extensive research in Additive Manufacturing (AM) shows, the powder characteristics, such as particle size and geometry, play an important role in determining the quality of powder layer and part fabricated with powder-based AM processes. It has been found that spherical particles result in better powder flowability and spreadability. An attempt to improve particle sphericity is to process the powder using the plasma spheroidization process, where the particles heat up, melt, and reshape to spheres. Several research works have been conducted to study the plasma spheroidization process and understand particle-plasma reactions. Although researchers have turned to simulations to overcome the difficulty of experimental study of such reactions, they only sufficed to characterize the powder particle size without evaluating the particle geometries. In this work, the plasma spheroidization process of copper powder was numerically examined to assess the impact of plasma spheroidization process on powder geometry and particle size. For the first time in literature, a method was proposed to quantify the particle geometry at each particle residence time. The results of simulation matched well with those of experiments.

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Section: Introductionmentioning

confidence: 99%

Numerical Study and Experimental Validation of Copper Powder Plasma Spheroidization Process

Sehhat

Leu²

2023

Preprint

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“…Various methods have been developed to prepare spherical powders. The radio frequency (RF) thermal plasma is one of the typical and effective methods for preparing spherical powders, especially for the refractory material, because it has some unique advantages [3][4][5][6][7]. For example, the high temperature (∼10 000 K) and high enthalpy (tens of MJ) of the plasma [8,9] can effectively reduce the time required to heat the particles to melt; steep temperature gradient [10] allows particles to rapidly solidify and maintain the spherical particle morphology; relatively slow velocity [11] to ensure the residence time of the particles in the high-temperature region of the plasma; electrode-free device structure to guarantee that the plasma environment is not contaminated during the spheroidization process and the high process purity of the treated particles.…”

Section: Introductionmentioning

confidence: 99%

Three-dimensional numerical simulation of heating and melting behaviors of cerium oxide powders in radio frequency thermal plasma

Zhou

et al. 2023

Plasma Sci. Technol.

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The present study aims at the numerical simulations of the melting process of cerium oxide particles in RF thermal plasma. The physical model and the calculating method were described firstly; the interaction between cerium oxide particles and plasma were analyzed; specific attention was given to the effects of particle initial size, injection velocity on the particle melting and trajectory in plasma. The influence of the temperature field and velocity field distribution of the plasma around the particle trajectory on the melting effect is analyzed, and the relationship between the heat absorption efficiency of the particles and the particle size reduction process is further determined; It is also found that there exists an optimal particle initial injection velocity which led to a more concentrated final particle size distribution and a more significant reduction of particle size. The results could provide effectively guidance for understanding the plasma spheroidization process of uranium dioxide and cerium dioxide powder particles.

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“…However, due to the complicated powder performance, especially powder spreading (Sehhat and Mahdianikhotbesara, 2021), some challenges are difficult to overcome, examples of which are porosity, large powder surface area and induced oxidation (Jerrard et al , 2010; Mower and Long, 2016; Behdani et al , 2020). Also, the high price of powder is a major challenge and cost driver for typical LAM processes; to solve this cost limitation, recently, the researchers have successfully implemented the cheaper types of powder to provide highly desirable part properties, although the price of alternative powder type is still higher than metal foils (Sehhat et al , 2021c).…”

Section: Introductionmentioning

confidence: 99%

Development and experimental study of an automated laser-foil-printing additive manufacturing system

Hung

Turk

Sehhat

et al. 2022

RPJ

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Purpose This paper aims to present the development and experimental study of a fully automated system using a novel laser additive manufacturing technology called laser foil printing (LFP), to fabricate metal parts layer by layer. The mechanical properties of parts fabricated with this novel system are compared with those of comparable methodologies to emphasize the suitability of this process. Design/methodology/approach Test specimens and parts with different geometries were fabricated from 304L stainless steel foil using an automated LFP system. The dimensions of the fabricated parts were measured, and the mechanical properties of the test specimens were characterized in terms of mechanical strength and elongation. Findings The properties of parts fabricated with the automated LFP system were compared with those of parts fabricated with the powder bed fusion additive manufacturing methods. The mechanical strength is higher than those of parts fabricated by the laser powder bed fusion and directed energy deposition technologies. Originality/value To the best knowledge of authors, this is the first time a fully automated LFP system has been developed and the properties of its fabricated parts were compared with other additive manufacturing methods for evaluation.

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A review on ICP powder plasma spheroidization process parameters

Cited by 25 publications

References 70 publications

Numerical Study and Experimental Validation of Copper Powder Plasma Spheroidization Process

Numerical Study and Experimental Validation of Copper Powder Plasma Spheroidization Process

Three-dimensional numerical simulation of heating and melting behaviors of cerium oxide powders in radio frequency thermal plasma

Development and experimental study of an automated laser-foil-printing additive manufacturing system

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