Impact of Atomization Pressure on the Particle Size of Nickel-Based Superalloy Powders by Numerical Simulation

Qing, Yongquan; Guo, Kailun; Liu, Chen; Qin, Youyi; Yu, Zhan; Shang, Shuo; Wei, Yanpeng; Yu, Bo; Liu, Changsheng

doi:10.3390/ma15093020

Cited by 7 publications

(3 citation statements)

References 29 publications

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“…During the primary break-up stage, the molten metal was broken up into unstable liquid bodies (i.e., liquid film), which in turn broke down into drops (figure 1) [31]. During the secondary break-up, the larger droplets, or liquid film were further broken up into smaller droplets in the supersonic expansion zone of the airflow (figures 1 and 2) [32]. The gas pressure and catheter length were vital of importance for the breakup of the discontinuous droplets in EIGA.…”

Section: Resultsmentioning

confidence: 99%

Effects of gas pressure and catheter length on the breakup of discontinuous NiTi droplets in electrode induction melting gas atomization

Xie,

Li,

Liu

et al. 2024

Mater. Res. Express

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NiTi powder used for selective laser melting has here been fabricated by the breakup of discontinuous droplets in electrode induction melting gas atomization (EIGA). The morphology, particle size distribution, and hollow ratio of the powder were characterized by scanning electron microscopy (SEM), laser particle size analyzer, and computed tomography (CT), respectively. The effects of gas pressure and catheter length on the particle size distribution and powder morphology were then studied. Furthermore, the effects of the classifier wheel speed on the particle size distribution and yield of the 15-53 μm powder in the classification process were also analyzed. The results showed that the average particle size (D50) of the NiTi powder first decreased and, thereafter, increased as the atomization gas pressure increased. This was also the situation with catheter length. Also, the yield of the 15-53 μm powder increased with an increase in the classifier wheel speed. The optimum parameters were a gas atomization pressure of 5 MPa, a tension length of 28 mm, and a classifier wheel speed of 660 r/min. For this optimized condition, the D50 value and the yield of the NiTi powder were 57.54 μm and 46.4%. In addition, the flowability, hollow ratio, and oxygen content were 15.8 s/50 g, 0.31%, and 450 ppm, respectively. 

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Section: Resultsmentioning

confidence: 99%

Effects of gas pressure and catheter length on the breakup of discontinuous NiTi droplets in electrode induction melting gas atomization

Xie,

Li,

Liu

et al. 2024

Mater. Res. Express

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show abstract

“…VIGA has a high yield ratio of fine powders which is similar to EIGA. Powders prepared by VIGA possess certain advantages, including high purity and good sphericity (figures 3(c-i)-(c-iii)) [118]. Taking Inconel 718 powders (figures 3(a-ii), (b-ii), and (c-ii)) as an example, VIGA powders exhibit a higher sphericity relative to that of GA and EIGA powders.…”

Section: Vigamentioning

confidence: 99%

“…This is because the flow velocity of the alloy liquid is too high and most of the particles solidify in a lower atomization atmosphere without complete crushing. The disorder of the two-phase flow field increases with increasing gas pressure [118], which is conducive to sufficient breakage of the melt, leading to a narrower particle size distribution and a decrease in the median and average particle size. Atomization pressure also influences the powder characteristics.…”

Section: Vigamentioning

confidence: 99%

Characterization, preparation, and reuse of metallic powders for laser powder bed fusion: a review

Sun,

Chen,

Liu

et al. 2023

Int. J. Extrem. Manuf.

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Laser powder bed fusion (L-PBF) has attracted significant attention since its inception, providing unprecedented advantages to fabricate metallic components with complex geometry. The quality and performance of as-printed alloys is an intricate function consisting of numerous factors linking the feedstock powders, manufacturing, and post-treatment. As the starting materials, powders play a critical role in influencing the printing consistency, total fabrication cost, and mechanical properties. In consideration of its importance for L-PBF, the present review aims to review the recent progress on metallic powders for L-PBF focusing on powder characterization, powder fabrication, and powder reuse. The methods of powder characterization and fabrication were presented in the beginning by analyzing the principles and corresponding advantages and limitations. Subsequently, the effect of powder reuse on the powder characteristics and mechanical performance of L-PBF parts is analyzed focusing on steels, nickel-based superalloys, Ti and Ti alloys, and Al alloys. The evolution trend of powders and as-printed parts varies for different alloy systems based on the existing studies, which makes the proposal of a unified reuse protocol infeasible. Finally, perspectives are presented to cater to the increasing applications of AM technologies for future investigations. The present state-of-the-art work can pave the way for the broad industrial applications of L-PBF by enhancing printing consistency and reducing the total cost from the perspective of powders.

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Investigation on the effect of the gas-to-metal ratio on powder properties and PBF-LB/M processability

Cacace

Boccadoro²,

Semeraro

2023

Prog Addit Manuf

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Metal powders for the laser powder bed fusion process are usually produced via gas atomization. However, due to the tight particle size distribution required for this application, the yield of the atomization process is low, resulting in a high-powder cost. In this work, atomization process parameters were varied to increase the gas-to-metal ratio to reduce the particle size distribution produced, and therefore increase the yield of the process. As a result, eight powders were produced starting from scrap AISI 136L material at different gas-to-metal ratio values, and the atomization process yield was successfully increased by 50%. First, the eight powders were characterized in terms of powder size, shape distributions, and flowability. Later, all powders were used to produce tensile specimens. The powders produced at higher yield exhibited a larger number of fine particles but slightly lower circularity, particularly in the coarse fraction. Furthermore, powders produced at a high gas-to-metal ratio demonstrated enhanced flowing properties and higher packing density. Consequently, these powders exhibited superior tensile performance, with ultimate tensile strength (UTS) ranging from 651 to 673 MPa and elongation values between 63 and 66%.

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Impact of Atomization Pressure on the Particle Size of Nickel-Based Superalloy Powders by Numerical Simulation

Cited by 7 publications

References 29 publications

Effects of gas pressure and catheter length on the breakup of discontinuous NiTi droplets in electrode induction melting gas atomization

Effects of gas pressure and catheter length on the breakup of discontinuous NiTi droplets in electrode induction melting gas atomization

Characterization, preparation, and reuse of metallic powders for laser powder bed fusion: a review

Investigation on the effect of the gas-to-metal ratio on powder properties and PBF-LB/M processability

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