Synthesis of Nb-based powder alloy by mechanical alloying and plasma spheroidization processes for additive manufacturing

Goncharov, Ivan; Razumov, Nikolay; Silin, A. O.; Ozerskoi, Nikolay Evgenievich; Shamshurin, A. I.; Kim, A.; Wang, Q.S.; Popovich, Anatoliy

doi:10.1016/j.matlet.2019.03.014

Cited by 43 publications

(11 citation statements)

References 15 publications

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“…The quality and properties of the feedstock materials depend a lot on the manufacturing process, which, in the case of metal powders for LPBF, can be quite varied [18,[62][63][64][65][66][67], ranging from rotary, water, and gas atomization [66][67][68][69][70] to the plasma rotating electrode process (PREP) [71,72]. Furthermore, in order to make the additive manufacturing process more cost-efficient and to reduce the price of the feedstock, the reuse of scraps and chips produced by traditional manufacturing of expensive metals and alloys (i.e., Ti-6Al-4V, aluminum) was proposed via spheroidization [73,74] and milling [75,76].…”

Section: Powder Feedstock Featuresmentioning

confidence: 99%

Material Reuse in Laser Powder Bed Fusion: Side Effects of the Laser—Metal Powder Interaction

Santecchia

Spigarelli

Cabibbo

2020

Metals

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Metal additive manufacturing is changing the way in which engineers and designers model the production of three-dimensional (3D) objects, with rapid growth seen in recent years. Laser powder bed fusion (LPBF) is the most used metal additive manufacturing technique, and it is based on the efficient interaction between a high-energy laser and a metal powder feedstock. To make LPBF more cost-efficient and environmentally friendly, it is of paramount importance to recycle (reuse) the unfused powder from a build job. However, since the laser-powder interaction involves complex physics phenomena and generates by-products which might affect the integrity of the feedstock and the final build part, a better understanding of the overall process should be attained. The present review paper is focused on the clarification of the interaction between laser and metal powder, with a strong focus on its side effects. Figure 1. Schematics of the laser powder bed fusion (LPBF) equipment. Adapted from Reference [9] with permission from Elsevier.While the market and the applications of laser powder bed fusion continuously and impressively grew in recent years, there is a common view across users and researchers concerning the repeatability of the process in terms of chemical composition and mechanical properties of the final parts, which are of paramount importance when challenging environmental or testing conditions are considered [10][11][12][13][14][15][16].The most typical approach to study the microstructural and mechanical properties of parts built by LPBF is to compare them with castings of the same alloy or, rather, the corresponding alloy since the starting material is metal powder rather than a fuse. However, in some existing alloys designed for cast and wrought parts, laser additive manufacturing processing results in cracking or other microstructure deficiencies [11,12,16,17]. It is worth noting that LPBF has more similarities with laser welding rather than casting, since the two laser-based techniques have some common features (i.e., melt-pool formation, moving heat source) [18]. However, process parameters are, in general, quite different in terms of laser power and scan speed, and the laser-matter interaction is much more complicated in LPBF processes, since the powder feedstock is inherently unstable and the solidified material undergoes multiple thermal cycles corresponding to the fusion of subsequent layers during the additive process [19][20][21][22]. Furthermore, owing to the similarities with welding and to the complicated interaction between laser and metal particles, when comparing laser powder bed fusion with other metal forming processes, it is evident that the range of processable alloys is very limited and the number of high-productivity commercially available alloys is even smaller [23]. One of the reasons behind this is that the level of metal powder sensitivity to the laser action during LPBF is not yet fully understood, despite the efforts of the scientific community to uncover it [24][25][26][27], and ...

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Section: Powder Feedstock Featuresmentioning

confidence: 99%

Material Reuse in Laser Powder Bed Fusion: Side Effects of the Laser—Metal Powder Interaction

Santecchia

Spigarelli

Cabibbo

2020

Metals

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“…While atomization techniques allow manufacturing of spherical powders, these technologies are rather costly, especially considering the complex compositions of intermetallic alloys. Mechanical alloying (MA), followed by the plasma spheroidization (PS) process, is an alternative approach to obtain spherical powders with reduced costs for application in AM [22,23]. Irregular MA powders are treated in a high-temperature plasma jet, resulting in rapid melting and solidification and leading to spherical powders [24].…”

Section: Introductionmentioning

confidence: 99%

Additive Manufacturing of Ti-48Al-2Cr-2Nb Alloy Using Gas Atomized and Mechanically Alloyed Plasma Spheroidized Powders

et al. 2020

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In this paper, laser powder-bed fusion (L-PBF) additive manufacturing (AM) with a high-temperature inductive platform preheating was used to fabricate intermetallic TiAl-alloy samples. The gas atomized (GA) and mechanically alloyed plasma spheroidized (MAPS) powders of the Ti-48Al-2Cr-2Nb (at. %) alloy were used as the feedstock material. The effects of L-PBF process parameters—platform preheating temperature—on the relative density, microstructure, phase composition, and mechanical properties of printed material were evaluated. Crack-free intermetallic samples with a high relative density of 99.9% were fabricated using 900 °C preheating temperature. Scanning electron microscopy and X-Ray diffraction analyses revealed a very fine microstructure consisting of lamellar α2/γ colonies, equiaxed γ grains, and retained β phase. Compressive tests showed superior properties of AM material as compared to the conventional TiAl-alloy. However, increased oxygen content was detected in MAPS powder compared to GA powder (~1.1 wt. % and ~0.1 wt. %, respectively), which resulted in lower compressive strength and strain, but higher microhardness compared to the samples produced from GA powder.

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“…In the recent years, the in situ approach for AM gained much attention among researches. [ 11–25 ] For instance, Promakhov et al [ 24 ] produced Inconel 625/TiB 2 MMC material applying self‐propagating high‐temperature synthesis (SHS). Obtained blocks were grinded to a coarse powder and then plasma spheroidized yielding spherical particles with TiB 2 reinforcements of 0.5–5 μm size.…”

Section: Introductionmentioning

confidence: 99%

Manufacturing Fe–TiC Composite Powder via Inert Gas Atomization by Forming Reinforcement Phase In Situ

et al. 2020

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Metal matrix composites (MMCs) are materials that have a ductile matrix reinforced with a hard ceramic phase. This combination gives advanced mechanical and functional properties, such as high yield and tensile strength, modulus, and wear resistance. [1-4] Therefore, these materials are widely utilized in automotive, aerospace, medicine, and other high-tech industries. Traditionally, MMC materials are fabricated via the powder metallurgy route, where metal and ceramic powders are premixed and then sintered. [5] As the reinforcement phase, carbides, oxides, nitrides, and borides are normally implemented. Due to the rapid development of the additive manufacturing (AM) market, there is a demand for new materials that can be fabricated additively including MMCs. Moreover, MMCs are normally hard to machine adjusting a semiproduct to a final shape. Thus, manufacturing a nearnet-shape MMC product is an attractive solution, which can further promote the introduction of AM techniques. Dadbakhsh et al. [6] reviewed several attempts of MMC manufacturing via laser powder bed fusion (L-PBF) dealing with Al-, Ti-, and steel-based materials. Specifically, Yuan et al. [7] produced AlSi10Mg-5.8 vol% TiC composite material finding the optimal parameters for the sufficient distribution of the TiC-phase during a L-PBF process. Gu et al. [8] fabricated the Ti/TiC composite revealing a dependence of the reinforcement phase shape and its distribution in the matrix on the L-PBF process parameters and TiC content (up to 22.5 wt%). AlMangour et al. [9] investigated 316 L/TiC MMC with varying reinforcement phase content from 2.5 to 15 vol%. These examples describe the ex situ addition of the reinforcement phase to the matrix by mixing metal and TiC powders prior to the printing process. As an alternative, it is possible to fabricate the reinforcement phase in situ bringing needed elements in contact. Tjong et al. [10] summarized the benefits of in situ formation of the reinforcement phase: enhanced thermodynamic stability, strong interfacial bonding, sufficient reinforcement phase distribution, and refinement, which further improve the mechanical properties of MMC. In the recent years, the in situ approach for AM gained much attention among researches. [11-25] For instance, Promakhov et al. [24] produced Inconel 625/TiB 2 MMC material applying self-propagating high-temperature synthesis (SHS). Obtained blocks were grinded to a coarse powder and then plasma spheroidized yielding spherical particles with TiB 2 reinforcements of 0.5-5 μm size. Thereby, this powder was successfully utilized for test samples fabrication by direct laser deposition technique (DLD). AlMangour et al. [12] utilized for L-PBF mechanically alloyed composite powder. For this experiment, 316L-Ti-graphite mixed powders were milled for 35 h

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Synthesis of Nb-based powder alloy by mechanical alloying and plasma spheroidization processes for additive manufacturing

Cited by 43 publications

References 15 publications

Material Reuse in Laser Powder Bed Fusion: Side Effects of the Laser—Metal Powder Interaction

Material Reuse in Laser Powder Bed Fusion: Side Effects of the Laser—Metal Powder Interaction

Additive Manufacturing of Ti-48Al-2Cr-2Nb Alloy Using Gas Atomized and Mechanically Alloyed Plasma Spheroidized Powders

Manufacturing Fe–TiC Composite Powder via Inert Gas Atomization by Forming Reinforcement Phase In Situ

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