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Powders Materials for Additive Manufacturing (AM)

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (20 May 2022) | Viewed by 6627

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Special Issue Editor

Prof. Dr. Patrick Masset

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Guest Editor

Faculty of Mechanical Engineering, Koszalin University of Technology, 75-453 Koszalin, Poland
Interests: powder and nano materials; coatings and surface engineering technologies; high temperature materials; electrochemical processes
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Powder materials are used in many industrial applications and processes, such as hot isostatic pressing (HIP), metal injection moulding (MIM), thermal spraying technologies, catalysis, welding, brazing, and so on. The design and manufacturing of metal powders have gained significant importance with the emergence of additive manufacturing technologies.

The development and utilisation of metal powder for additive manufacturing encompass many facets including composition, thermodynamic properties and microstructure, the impact of the manufacturing technologies, and dedicated characterisation methods for suitable powder for AM processes.

In addition, the evaluation of the properties of such materials, in relation to their application conditions, includes their processing during the printing steps and including its recycling, with adequate strategies depending on the AM process.

In this Special Issue, the latest progresses in designing powders materials for additive manufacturing (AM) are thoroughly highlighted and discussed.

It is my pleasure to invite you to submit a manuscript for this Special Issue. Full papers, communications, and reviews are all welcome.

Prof. Dr. Patrick Masset
Guest Editor

Manuscript Submission Information

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Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

powder materials
alloys: aluminium, titanium, steels, incalloy, high entropy alloys
atomisation technologies: gas or water atomisation, ultrasonic assisted plasma atomisation, centrifugal atomisation
flowability
sphericity
particle size distribution
reactivity

Published Papers (3 papers)

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Research

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16 pages, 3889 KiB

Open AccessArticle

Evolution of Fe-Rich Phases in Thermally Processed Aluminum 6061 Powders for AM Applications

by Kyle Tsaknopoulos, Caitlin Walde, Derek Tsaknopoulos and Danielle L. Cote

Materials 2022, 15(17), 5853; https://doi.org/10.3390/ma15175853 - 25 Aug 2022

Viewed by 1129

Abstract

Gas-atomized powders are frequently used in metal additive manufacturing (MAM) processes. During consolidation, certain properties and microstructural features of the feedstock can be retained. Such features include porosity, secondary phases, and oxides. Of particular importance to alloys such as Al 6061, secondary phases found in the feedstock powder can be directly related to those of the final consolidated form, especially for solid-state additive manufacturing. Al 6061 is a heat-treatable alloy that is commonly available in powder form. While heat treatments of 6061 have been widely studied in wrought form, little work has been performed to study the process in powders. This work investigates the evolution of the Fe-containing precipitates in gas-atomized Al 6061 powder through the use of scanning and transmission electron microscopy (SEM and TEM) and energy dispersive X-ray spectroscopy (EDS). The use of coupled EDS and thermodynamic modeling suggests that the as-atomized powders contain Al₁₃Fe₄ at the microstructure boundaries in addition to Mg₂Si. After one hour of thermal treatment at 530 °C, it appears that the dissolution of Mg₂Si and Al₁₃Fe₄ occurs concurrently with the formation of Al₁₅Si₂M₄, as suggested by thermodynamic models. Full article

(This article belongs to the Special Issue Powders Materials for Additive Manufacturing (AM))

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10 pages, 1722 KiB

Open AccessArticle

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

by Yongquan Qing, Kuaikuai Guo, Chen Liu, Youyi Qin, Yu Zhan, Shang Shuo, Yanpeng Wei, Bo Yu and Changsheng Liu

Materials 2022, 15(9), 3020; https://doi.org/10.3390/ma15093020 - 21 Apr 2022

Cited by 6 | Viewed by 2033

Abstract

Vacuum induction melting gas atomization (VIGA) has evolved as an important production technique of superalloy powders used in additive manufacturing. However, the development of powder preparation techniques is limited because the crushing process of gas-atomized metal melt is difficult to characterize by conventional experimental methods. Herein, we report the application of computational fluid dynamics to simulate the breaking behavior of droplets in the process of preparing nickel-based superalloy powders by VIGA, as well as the results on the effect of gas pressure on the atomization process and powder particle size distribution of metal melt. In the process of primary atomization, the crushing morphology of superalloy melt shows an alternate transformation of umbrella shapes and inverted mushroom cloud shapes, and with the increase in atomization pressure, the disorder of the two-phase flow field increases, which is conducive to sufficient breakage of the melt. Most importantly, in the process of secondary atomization and with the increasing atomization pressure, the particle size distribution becomes narrower, the median particle diameter and average particle size decrease, and the decreasing trend of the particle size increases gradually. The simulation results are compliant with the performed nickel-based superalloy powder preparation tests. This study provides insight into the production and process optimization of superalloy powder prepared by the VIGA method. Full article

(This article belongs to the Special Issue Powders Materials for Additive Manufacturing (AM))

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Review

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25 pages, 3131 KiB

Open AccessReview

An Influence of Oxygen Flow Rate and Spray Distance on the Porosity of HVOF Coating and Its Effects on Corrosion—A Review

by Ali Raza, Faiz Ahmad, Thar M. Badri, M. R. Raza and Khurshid Malik

Materials 2022, 15(18), 6329; https://doi.org/10.3390/ma15186329 - 12 Sep 2022

Cited by 20 | Viewed by 2504

Abstract

Thermal spray coating, exceptionally high-velocity oxyfuel (HVOF), improves the corrosion resistance and wear of metal. Coating parameters play a vital role in the properties of the coating. The quality of coating can be increased by selecting appropriate coating parameters. In the case of HVOF, the oxygen flow rate and spray distance are the most significant parameters that directly influence the porosity and corrosion resistance of the coating. Porosity is essential in thermal barrier coatings for low thermal conductivity, but there is a limit of porosity beyond which it can cause failure. Hence, understanding the effects of these parameters is essential to evaluate and further minimize the porosity in order to improve the corrosion resistance and durability of the thermal barrier coating. This article reviews hot corrosion in thermal barrier coatings, the stages of corrosion, the importance of spray parameters, and the effect of the oxygen flow rate and spray distance on the corrosion resistance of HVOF-sprayed coatings. Afterwards, the coating materials, the substrate, the flow rate of oxygen, the spray distance, and the fuel used during the HVOF spraying process from recent articles are summarized. In summary, this review compares the flow rate of oxygen and the spray distance with the corrosion capacity of the coating under different corrosive environments and materials to optimize these parameters for high-quality coating, which would sustain under high temperatures for future applications. Full article

(This article belongs to the Special Issue Powders Materials for Additive Manufacturing (AM))

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