The Application of Globular Water-Atomized Iron Powders for Additive Manufacturing by a LENS Technique
Abstract
:1. Introduction
2. Materials and Methods
3. Results and Discussion
3.1. Powder Characterization
3.2. The Role of Vibration in the Powder Feed System
3.3. Characterization of Fabricated Samples
4. Conclusions
- 1.
- The four, water-atomized, nonspherical ATOMET powders—designated as ATOMET 28, 1001, 4701, and 4801—were characterized by an overall rounded, globular morphology and relatively wide particle size distribution from 20 to 200 µm.
- 2.
- As an exception, the ATOMET 28 powder was characterized by a strong inhomogeneity of particle size and irregular polyhedral shape of powder particles with sharp edges.
- 3.
- Before the LENS processing of solid samples, all four ATOMET powders were pre-sieved to the size range 40–150 µm.
- 4.
- The nearly cubic solid sample from the LENS-fabricated ATOMET 28 powder exhibited the largest cross-sectional (2D) porosity of 4.2% and bulk porosity of 3.9%, the latter obtained from the microtomography measurements. This is most likely due to the strong inhomogeneity of particle size and irregular polyhedral shape of powder particles with sharp edges present in this particular powder. In contrast, the cross-sectional porosities of bulk, solid, nearly cubic samples from the other LENS-fabricated ATOMET powders exhibited very low porosities within the range 0.03–0.1%.
- 5.
- Surprisingly, the solid sample from the LENS-fabricated reference, purely spherical Fe 99.8 powder, exhibited the second largest porosity of 1.1%, after that of the pre-sieved, nonspherical ATOMET 28 powder.
- 6.
- Incorporation of vibrations into the LENS powder feeding system substantially improved the flow rate vs. feeding rate dependence, making it completely linear with excellent coefficients of fit R2 = 0.99.
- 7.
- Interestingly, the reference powder Fe 99.8 always exhibited a linear dependence between the flow rate vs. feeding rate regardless of whether or not vibrations were incorporated into the powder feeding system. Apparently, a purely spherical powder eliminates any LENS feeding problems.
Author Contributions
Funding
Acknowledgments
Conflicts of Interest
References
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ATOMET Powder | Element (wt %) | |||||||
---|---|---|---|---|---|---|---|---|
Fe | C | O | S | Mn | Mo | Ni | Cr | |
28 | Bal. | 0.042 | 0.110 | 0.011 | na | na | na | na |
1001 | Bal. | 0.004 | 0.070 | 0.011 | 0.169 | na | na | na |
4701 | Bal. | 0.014 | 0.170 | 0.009 | 0.447 | 1.011 | 0.897 | 0.471 |
4801 | Bal. | 0.005 | 0.070 | 0.006 | 0.137 | 0.537 | 3.945 | na |
Fe 99.8 | Bal. | 0.050 | 0.120 | n/a | n/a | n/a | n/a | n/a |
ATOMET 28 | ATOMET 1001 | ATOMET 4701 | ATOMET 4801 | Fe 99.8 | ||
---|---|---|---|---|---|---|
Number of coils | 3 | 3 | 3 | 3 | 3 | |
Gas (L/min) | Laser | 40 | 40 | 40 | 40 | 40 |
Powder | 2.8 | 2.8 | 2.8 | 2.8 | 2.8 | |
Power (W) | 300 | 300 | 300 | 300 | 300 | |
Feeding rate (RPM) | 6 | 6 | 6 | 6.2 | 4.6 | |
Travel (mm/s) | Contour | 10.5 | 9.5 | 9.5 | 9.5 | 11.5 |
Filling | 15 | 15 | 15 | 15 | 15 | |
Set up movement | 10 | 10 | 10 | 10 | 10 | |
Layer thickness (mm) | 0.2 | 0.2 | 0.2 | 0.2 | 0.2 | |
Hatch | deg | 0°/90° | 0°/90° | 0°/90° | 0°/90° | 0°/90° |
(mm) | 0.3 | 0.35 | 0.3 | 0.3 | 0.3 | |
Hatch shrink | 0.05 | 0.05 | 0.05 | 0.05 | 0.05 | |
Vibration | 1 bar, 45° | 1 bar, 45° | 1 bar, 45° | 1 bar, 45° | 1 bar, 45° | |
Remarks | Acc/dec: 40,000 | Acc/dec: 40,000 | Acc/dec: 40,000 | Acc/dec: 40,000 | Acc/dec: 40,000 |
ATOMET Powder | a (mm) | b (mm) | c (mm) |
---|---|---|---|
28 | 10.51 | 10.55 | 10.52 |
1001 | 10.47 | 10.40 | 10.42 |
4701 | 10.45 | 10.40 | 10.47 |
4801 | 10.49 | 10.41 | 10.50 |
Fe 99.8 | 10.53 | 10.50 | 10.47 |
ATOMET Powder | Lateral Surface | Top Surface | ||
---|---|---|---|---|
Ra (µm) | Wa (µm) | Ra (µm) | Wa (µm) | |
28 | 10.0 ± 0.9 | 3.7 ± 0.5 | 13.1 ± 1.4 | 2.3 ± 0.6 |
1001 | 13.7 ± 1.1 | 5.8 ± 0.6 | 22.9 ± 1.1 | 21.3 ± 1.5 |
4701 | 12.1 ± 1.3 | 2.9 ± 0.4 | 25.3 ± 1.4 | 13.7 ± 1.1 |
4801 | 5.4 ± 0.8 | 1.0 ± 0.1 | 10.5 ± 1.8 | 10.0 ± 1.5 |
Fe 99.8 | 11.4 ± 1.2 | 4.0 ± 0.4 | 20.1 ± 1.2 | 4.9 ± 0.7 |
ATOMET and Reference Powder | Porosity LENS-Fabricated Sample (%) |
---|---|
28 | 4.2 |
1001 | 0.1 |
4701 | 0.03 |
4801 | 0.1 |
Fe 99.8 | 1.1 |
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Durejko, T.; Aniszewska, J.; Ziętala, M.; Antolak-Dudka, A.; Czujko, T.; Varin, R.A.; Paserin, V. The Application of Globular Water-Atomized Iron Powders for Additive Manufacturing by a LENS Technique. Materials 2018, 11, 843. https://doi.org/10.3390/ma11050843
Durejko T, Aniszewska J, Ziętala M, Antolak-Dudka A, Czujko T, Varin RA, Paserin V. The Application of Globular Water-Atomized Iron Powders for Additive Manufacturing by a LENS Technique. Materials. 2018; 11(5):843. https://doi.org/10.3390/ma11050843
Chicago/Turabian StyleDurejko, Tomasz, Justyna Aniszewska, Michał Ziętala, Anna Antolak-Dudka, Tomasz Czujko, Robert A. Varin, and Vlad Paserin. 2018. "The Application of Globular Water-Atomized Iron Powders for Additive Manufacturing by a LENS Technique" Materials 11, no. 5: 843. https://doi.org/10.3390/ma11050843
APA StyleDurejko, T., Aniszewska, J., Ziętala, M., Antolak-Dudka, A., Czujko, T., Varin, R. A., & Paserin, V. (2018). The Application of Globular Water-Atomized Iron Powders for Additive Manufacturing by a LENS Technique. Materials, 11(5), 843. https://doi.org/10.3390/ma11050843