Novel Cold Crucible Ultrasonic Atomization Powder Production Method for 3D Printing

Żrodowski, Łukasz; Wróblewski, Rafał; Choma, Tomasz; Morończyk, Bartosz; Ostrysz, Mateusz; Leonowicz, M.; Łacisz, Wojciech; Błyskun, P.; Wróbel, Jan; Cieślak, Grzegorz; Wysocki, Bartłomiej; Żrodowski, Cezary; Pomian, Karolina

doi:10.3390/ma14102541

Cited by 27 publications

(15 citation statements)

References 34 publications

(41 reference statements)

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“…The principle of metal powder production through UA has been known for a long time already and has at first been applied to elements and alloys with low liquidus temperatures, such as Pb, Sb, or Sn-Zn alloys, for example, for solders [20][21][22]. Recent studies have also successfully applied a UA approach to materials with higher liquidus temperatures such as steels [23,24], Ni-Mn-Ga, Ti alloys, and Fe-Cr-Mn-Ni high entropy alloys [23]. In the experiment of Alavi and Harimkar [24], a laser beam melts the bulk substrate material, which is screwed on top of a ultrasonic probe.…”

Section: Discussionmentioning

confidence: 99%

“…However, for brittle refractory metal-based materials, this setup is difficult to realize since the substrate has to be machined with a screw thread. In the approach of Żrodowsky et al [23], the setup is similar to the one discussed in this study, but it used a material feedstock that is inductively molten before being applied onto the sonotrode platform. In contrast, the commercially available device we presented can be easily incorporated in a standard, lab-based arc-melting route to produce tailored alloy composition feedstock.…”

Section: Discussionmentioning

confidence: 99%

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Flexible Powder Production for Additive Manufacturing of Refractory Metal-Based Alloys

Hinrichs¹,

Kauffmann²,

Schliephake³

et al. 2021

Metals

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The quality and properties of metal powders are essential for powder metallurgical (PM) processes in general and for additive manufacturing (AM) processing routes in particular. Thus, a variety of atomization technologies were established meeting the multiple needs of the different processing technologies. However, the production of refractory metal alloy powder remains challenging due to their high liquidus temperatures (>2000 °C), the formation of brittle intermetallic phases, as well as the reactivity with and sensitivity to interstitials of the constituting elements. In this contribution, powders made of Mo-20Si-52.8-Ti (at.%) were produced by a novel ultrasonic atomization (UA) process at laboratory-scale using an industrial electrode induction gas atomization (EIGA) process with a modified electrode concept for the first time. UA allows flexibility in alloy composition due to the arc melting-based principle, while the EIGA electrode is PM manufactured from elemental powders to provide similar flexibility on a larger scale. The powders resulting from these two processes were compared with respect to size distribution, sphericity, microstructure and phase constitution, chemical composition, and interstitial impurity content. In addition, several powder batches were produced with the UA process in order to assess the process reliability and stability. The properties, quality, and quantities of UA powders perfectly meet the requests for alloy development for powder bed fusion AM, while the modified EIGA process allows the upscaling of the alloy powder quantities.

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Section: Discussionmentioning

confidence: 99%

Section: Discussionmentioning

confidence: 99%

Flexible Powder Production for Additive Manufacturing of Refractory Metal-Based Alloys

Hinrichs¹,

Kauffmann²,

Schliephake³

et al. 2021

Metals

View full text Add to dashboard Cite

show abstract

“…Fe-based soft magnetic amorphous/nanocrystalline alloys with high saturation magnetization, low coercivity, low magnetic loss and low cost are expected to solve the problem of poor performance stability of traditional soft magnetic materials under high-frequency conditions and also provide reserve for ideal materials for integrated inductance forming [ 3 ]. At present, traditional casting technologies, such as the copper-mold-casting method and single-roll melt spinning, can be used to produce bulk metallic glasses (BMGs) with a certain thickness, but these methods are only applicable to systems with high-glass-forming ability (GFA), such as Zr, La, Pd, etc., due to the limitation of cooling rate (order of 10 2 K·s −1 ) [ 4 , 5 , 6 , 7 ]. Therefore, Fe-based amorphous alloys with poor GFA are usually produced by atomization with sufficient cooling rate in industry, and then BMGs with a certain size can be fabricated by consolidation technology [ 8 ].…”

Section: Introductionmentioning

confidence: 99%

Study of Bulk Amorphous and Nanocrystalline Alloys Fabricated by High-Sphericity Fe84Si7B5C2Cr2 Amorphous Powders at Different Spark-Plasma-Sintering Temperatures

et al. 2022

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The new generation of high-frequency and high-efficiency motors has high demands on the soft magnetic properties, mechanical properties and corrosion resistance of its core materials. Bulk amorphous and nanocrystalline alloys not only meet its performance requirements but also conform to the current technical concept of integrated forming. At present, spark plasma sintering (SPS) is expected to break through the cooling-capacity limitation of traditional casting technology with high possibility to fabricate bulk metallic glasses (BMGs). In this study, Fe84Si7B5C2Cr2 soft magnetic amorphous powders with high sphericity were prepared by a new atomization technology, and its characteristic temperature was measured by DSC to determine the SPS temperature. The SEM, XRD, VSM and universal testing machine were used to analyze the compacts at different sintering temperatures. The results show that the powders cannot be consolidated by cold pressing (50 and 500 MPa) or SPS temperature below 753 K (glass transition temperature Tg = 767 K), and the tap density is only 4.46 g·cm−3. When SPS temperature reached above 773 K, however, the compact could be prepared smoothly, and the density, saturation magnetization, coercivity and compressive strength of the compacts increased with the elevated sintering temperature. In addition, due to superheating, crystallization occurred even when the sintering temperature was lower than 829 K (with the first crystallization onset temperature being Tx1 = 829 K). The compact was almost completely crystallized at 813 K, resulting in a sharp increase in the coercivity of the compact from 55.55 A·m−1 at 793 K to 443.17 A·m−1. It is noted that the nanocrystals kept growing in size as the temperature increased to 833 K, which increased the coercivity remarkably but showed an enhanced saturation magnetization.

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“…To obtain that state, the melted alloy needs to be cooled at a speed higher than the critical cooling rate. This cooling stops dynamic atom diffusion and enables the development of an amorphous solid-state structure of a metal alloy [ 3 ].…”

Section: Introductionmentioning

confidence: 99%

“…One of the methods that ensure cooling with a high enough speed is the gas atomization shown in Figure 1 . Researchers [ 3 , 4 , 5 ] proved that atomization is a proper method to prepare amorphous alloys in a powder form. However, research shows that fully vitrification of powders depends on the size of obtained particles [ 6 ] and glass-forming ability of the processed alloy [ 7 ].…”

Section: Introductionmentioning

confidence: 99%

Investigation of Mechanical and Magnetic Properties of Co-Based Amorphous Powders Obtained by Atomization

et al. 2021

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Properties of Co-based alloys with high Glass Forming Ability (GFA) in the form of powder are still not widely known. However, powders of high GFA alloys are often used for the development of bulk metallic glasses by additive manufacturing. In this work Co47.6B21.9Fe20.4Si5.1Nb5% at. and Co42B26.5Fe20Ta5.5Si5Cu1% at. were developed by gas-atomization. Obtained powders in size 50–80 µm were annealed at Tg and Tx of each alloy. Then SEM observation, EDS analyses, differential thermal analysis, X-ray diffraction, nanoindentation, Mössbauer, and magnetic properties research was carried out for as-atomized and annealed states. The gas atomization method proved to be an efficient method for manufacturing Co-based metallic glasses. The obtained powder particles were spherical and chemically homogeneous. Annealing resulted in an increase of mechanical properties such as hardness and the elastic module of Co47.6B21.9Fe20.4Si5.1Nb5% at and Co42B26.5Fe20Ta5.5Si5Cu1%, which was caused by crystallization. The magnetic study shows that Co47.6B21.9Fe20.4Si5.1Nb5 and Co42B26.5Fe20Ta5.5Si5Cu1 are soft magnetic and semi-hard magnetic materials, respectively.

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Novel Cold Crucible Ultrasonic Atomization Powder Production Method for 3D Printing

Cited by 27 publications

References 34 publications

Flexible Powder Production for Additive Manufacturing of Refractory Metal-Based Alloys

Flexible Powder Production for Additive Manufacturing of Refractory Metal-Based Alloys

Study of Bulk Amorphous and Nanocrystalline Alloys Fabricated by High-Sphericity Fe84Si7B5C2Cr2 Amorphous Powders at Different Spark-Plasma-Sintering Temperatures

Investigation of Mechanical and Magnetic Properties of Co-Based Amorphous Powders Obtained by Atomization

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