In this work, three kinds of tungsten powders with different particle sizes were spheroidized by radio-frequency (RF) inductively coupled plasma spheroidization. The spheroidization behavior of these tungsten powders was investigated and compared. Th...
The Al2O3 + TiO2 coatings are of the interest of surface technology and tribology due to their good wear resistance and enhanced toughness comparing to pure Al2O3 coatings. However, the detailed effect of the used feedstock powder, is often neglected...
In metal fused deposition modeling (FDM), performance is governed by feedstock formulation, most critically the metal solid loading, while binder selection is constrained by environmental impacts and limited recyclability. This study investigates the...
Using feedstock containing discrete dual or multi powders leads to segregation in the powder bed of additive manufacturing processes. In the present study, a new impregnated hybrid binder with properties closer to those of the base powder is develope...
FeAlSi intermetallics are materials with promising high-temperature mechanical properties and oxidation resistance. Nevertheless, their production by standard metallurgical processes is complicated. In this study, preparation of powders by mechanical...
One of the main limitations for widespread additive manufacturing is availability and processability of the precursor materials feedstock. For the first time, this study reports the development of a “pomegranate-like” structured TiB2-Si c...
The applications of Nd-Fe-B-based magnets are experiencing significant diversification to achieve efficiency and miniaturization in different technologies. Metal injection molding (MIM) provides new opportunities to manufacture Nd-Fe-B magnets with h...
The microstructure and mechanical properties of a 4130-grade steel processed by L-PBF using a feedstock of low-cost water atomized powder have been investigated considering the effects of powder recycling. Chemical analysis of the recycled powder sho...
Yttria-stabilized zirconia (YSZ) hollow sphere (HS) powder is a novel potential feedstock material for the plasma spraying of next generation advanced thermal barrier coatings with low thermal conductivity and high sintering resistibility. In this st...
In the present state of the art, highly spherical alloy powders are employed as feedstock in powder bed fusion processes. These powders are characterized by high flowability and apparent density. Their elaborate fabrication process is reflected in hi...
The detrimental effect of nitrogen and oxygen when it comes to the precipitation of the strengthening γ’’ and γ’ phases in Alloy 718 is well-known from traditional manufacturing. Hence, the influence of the two processing atmospheres, namely argon an...
Controlling injection parameters is paramount when it comes to producing high-quality green parts using powder injection molding. This work combines experimental and numerical approaches to study the impact of injection parameters on mold in-cavity p...
Splat morphology is an important factor that influences the mechanical properties and durability of thermal barrier coatings (TBCs). In this study, yttria-stabilized zirconia (YSZ) coatings with different lamellar interface morphologies were deposite...
When cold spraying is performed at a velocity equivalent to or greater than a specific material-dependent critical velocity, powders suffer intensive plastic deformation and localized heating of interacting surfaces. The thermomechanical reaction of...
W-20 wt.% Cu pseudo-alloys were produced via powder injection molding (PIM) with powders prepared thermochemically. Bonding treatment and ball milling (BTBM) were used, and the effects of BTBM on the characteristics of the powders, rheological proper...
In order to provide effective solid lubrication to Ni3Al coating, 10 wt.% Ag and different amounts of MoO3 solid lubricant were mechanically mixed with the SHSed Ni3Al powder and sprayed HVOF. Microstructure, mechanical properties, and tribological b...
In this study, the development of a polyoxymethylene (POM) feedstock material for the powder bed fusion (PBF) of polymers is outlined. POM particles are obtained via liquid-liquid phase separation (LLPS) and precipitation, also known as the solution-...
The binder plays the most important role in the metal injection molding (MIM) process. It provides fluidity of the feedstock mixture and adhesion of the powder to keep the molded shape during injection molding. The binder must provide strength and co...
Due to elevated temperatures and high vacuum levels in electron beam melting (EBM), spatter formation and accumulation in the feedstock powder, and sublimation of alloying elements from the base feedstock powder can affect the feedstock powder’s reus...
Within this contribution, the effect of grinding media wear on the melt crystallisation of polybutylene terephthalate (PBT) is addressed. PBT was wet ground in a stirred media mill in ethanol using different grinding media beads (silica, chrome steel...
In the past decade, the sales of metal additive manufacturing systems have increased intensely. In particular, PBF-LB/M systems (powder bed fusion of metals using a laser-based system) represent a technology of great industrial interest, in which met...
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 ox...
This work represents a preliminary study of atmospheric plasma-sprayed (APS) Yttria-Stabilized Zirconia (YSZ)-based thermal barrier coatings (TBCs) deposited on forged and additive manufactured (AM) HAYNES®282® (H282) superalloy substrates. T...
Over the last 20 years, there has been growing research and development investment to exploit the benefits of wire deposition additive manufacturing (AM) for the production of near-net shape components in aircraft and space applications. The wire fee...
The two-step PM (powder metallurgy)-route procedure was proposed to fabricate a super-engineering plastic gear directly from powder feedstock. Its lightweight, fully dense integrity and high-stiffness has been found to be suitable for reducers in rob...
This paper investigates new approaches for the blending and plastification of ceramic powder with a binder to form fused deposition of ceramic (FDC) feedstock. The fabrication of highly filled ceramic filaments was accomplished using the granulation...
Electrical explosion of aluminum wires has been shown to be a versatile method for the preparation of bimodal nano/micro powders. The energy input into the wire has been found to determine the relative content of fine and coarse particles in bimodal...
Cermet coatings deposited using high-velocity oxy-fuel (HVOF) are widely used due to their excellent wear and corrosion resistance. The new agglomeration–rapid sintering method is an excellent candidate for the preparation of WC–Co–...
The low deposition efficiency in directed energy deposition (DED) has prompted the reuse of powders that do not fuse to the builds to make additive manufacturing more sustainable. It is unknown, however, how the properties of the powder and deposited...
ASTM (52900:2015) classifies material extrusion (MEX) as an additive manufacturing (AM) technology that relies on the extrusion of a feedstock, which could be constituted by powder material and binder/additives [...]
Powder injection melting (PIM) and material extrusion additive manufacturing (MEAM) are promising production technologies that allow us to obtain products from modern composite materials. These technologies make it possible to obtain products of comp...
The capability of self-propagating high-temperature synthesis (SHS) to produce powders that are characterized by a high sintering ability, owing to high heating and cooling rates inherent to the exothermic reaction, is of a special interest for the i...
Ti6Al4V-HA composites have been recognized for their potential for biomedical implantation purposes. In the present study, Ti6Al4V-HA composites were fabricated by Powder Injection Molding (PIM) route. Ti6Al4V-HA feedstock at a ratio of 87:13 vol.% w...
Characterizing powder feedstock is crucial for ensuring the quality and reliability of parts produced through metal additive manufacturing (AM). The morphology of particles impacts the flowability, packing density, and spreadability of powders, affec...
Toxic metal reduction is at the forefront of many design considerations today; additive manufacturing has the ability to combine materials in ways other traditional processes cannot and has the potential to offer unique solutions to reduce hazardous...
The particle shape influences the part properties in laser powder bed fusion, and powder flowability and powder layer density (PLD) are considered the link between the powder and part properties. Therefore, this study investigates the relationship be...
Laser-Powder Bed Fusion (L-PBF) of metallic parts is a highly multivariate process. An understanding of powder feedstock properties is critical to ensure part quality. In this paper, a detailed examination of two commercial stainless steel 316L powde...
Due to the processes solid-state nature, cold gas-dynamic spray metal additive manufacturing may be considered microstructurally and micromechanically retentive, such that properties of the feedstock material are refined and partially retained, influ...
Additive manufacturing (AM) of metals and in particular laser powder bed fusion (LPBF) enables a degree of freedom in design unparalleled by conventional subtractive methods. To ensure that the designed precision is matched by the produced LPBF parts...
In the thermal spraying process, the porosity of ceramic coatings contributes directly to the efficiency of the thermal insulation. The size, shape, and distribution of the pores determine the level of both thermal and sintering resistance. In this w...
The use of pre-alloyed powders as high-entropy alloy (HEA) coating precursors ensures a predetermined (unaltered) elemental composition of the coating with regard to the feedstock powder. At the same time, it is interesting to tackle a more challengi...
This article deals with rheological and solvent extraction behavior of stainless steel 316L feedstocks using Restaurant Waste Fats and Oils (RWFO) from grease traps as binder components along with Polypropylene (PP) copolymer as a backbone binder. Op...
In this work, three commercially available aluminum alloy systems (Al 2024, Al 6061, and Al 7075) were considered to explicitly capture the differences in material properties associated with a rapidly solidified, gas-atomized particulate feedstock as...
The formulation of a high dielectric permittivity ceramic/polymer composite feedstock for daylight vat photopolymerization 3D printing (3DP) is demonstrated, targeting 3DP of devices for microwave and THz applications. The precursor is composed of a...
High Nb-containing TiAl alloy with a nominal composition of Ti-45Al-8.5Nb-0.2W-0.2B-0.02Y (at %) was fabricated by metal injection moulding (MIM) technology with an improved wax-based binder. The critical powder loading and feedstock rheological beha...
Ceramic injection molding is a near-net shape-processing technique, producing ceramic components with low tooling costs and complex shapes. In this paper, ZrO2 ceramics with high loading content in the green part were prepared by powder modification...
This study reveals the effect of TiB2 particles on the mechanical and tribological properties of Fe3Al-TiB2 composite coatings against an alumina counterpart. The feedstock was produced by milling Fe3Al and TiB2 powders in a high energy ball mill. Th...
In advanced powder metallurgy technologies such as metal injection molding (MIM) and material extrusion technology (MEX), the intricate synergy between binder components and metallic powders within feedstocks is predominant, dictating the technologic...
Despite the large number of studies devoted to different compositions of polymer binders for PIM technology, the actual task is still a comparative analysis of the properties of different types of binders to determine their advantages and disadvantag...
Titanium is one of the most attractive materials for biomedical applications due to having excellent biocompatibility accompanied by good corrosion resistance. One popular processing technique for Ti is Metal Injection Moulding (MIM). However, there...
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