Laser powder bed fusion additive manufacturing of oxide dispersion strengthened steel using gas atomized reaction synthesis powder

Horn, Timothy; Rock, Christopher; Kaoumi, Djamel; Anderson, Iver E.; White, Emma; Prost, Tim; Rieken, Joel; Saptarshi, Sourabh; Schoell, Ryan; DeJong, Matthew J.; Timmins, Sarah; Forrester, Jennifer; Lapidus, Saul H.; Napolitano, Ralph E.; Zhang, Dalong; Darsell, Jens T.

doi:10.1016/j.matdes.2022.110574

Cited by 23 publications

(1 citation statement)

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“…Traditional approaches for producing an ODS material involve long-duration mechanical alloying combined with powder metallurgy consolidation methods such as spark plasma sintering and hot isostatic pressing [ 7 , 8 , 9 ]. Another process called gas-atomized reactive (GAR) atomization has been employed to form oxide particles within metal powder particles by the controlled introduction of oxygen into the argon gas atomization process [ 10 , 11 , 12 , 13 ]. Similarly, some studies have formed the oxide particles during LPBF by the addition of oxygen to the process atmosphere [ 14 , 15 ].…”

Section: Introductionmentioning

confidence: 99%

In Situ Reactive Formation of Mixed Oxides in Additively Manufactured Cobalt Alloy

Lopez,

Cerne,

et al. 2023

Materials

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Oxide-dispersion-strengthened (ODS) alloys have long been considered for high temperature turbine, spacecraft, and nuclear reactor components due to their high temperature strength and radiation resistance. Conventional synthesis approaches of ODS alloys involve ball milling of powders and consolidation. In this work, a process-synergistic approach is used to introduce oxide particles during laser powder bed fusion (LPBF). Chromium (III) oxide (Cr2O3) powders are blended with a cobalt-based alloy, Mar-M 509, and exposed to laser irradiation, resulting in reduction–oxidation reactions involving metal (Ta, Ti, Zr) ions from the metal matrix to form mixed oxides of increased thermodynamic stability. A microstructure analysis indicates the formation of nanoscale spherical mixed oxide particles as well as large agglomerates with internal cracks. Chemical analyses confirm the presence of Ta, Ti, and Zr in agglomerated oxides, but primarily Zr in the nanoscale oxides. Mechanical testing reveals that agglomerate particle cracking is detrimental to tensile ductility compared to the base alloy, suggesting the need for improved processing methods to break up oxide particle clusters and promote their uniform dispersion during laser exposure.

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