Defect and satellite characteristics of additive manufacturing metal powders
Date
2022-02-18
Authors
Xiong, Lianghua
Chuang, Andrew Chihpin
Thomas, Jonova
Prost, Timothy
White, Emma
Anderson, Iver
Singh, Dileep
Major Professor
Advisor
Committee Member
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Publisher
Iowa State University Digital Repository, Ames IA (United States)
Abstract
Metal additive manufacturing (AM) requires high-quality metal powders to three-dimensionally (3D) print metallic components with complex and customizable geometries. The lack of quantification of AM metal powders creates quality control challenges for 3D printed components, increases the uncertainty of printing reliability and net cost of inspected and certified printed components, and reduces the recyclability of used powders. However, critical characteristics of AM metal powders that are decisive factors for the 3D printing process, such as internal porosity, contamination, and satellite feature, remain ambiguous. In this work, we developed a novel approach to 3D quantify key characteristics of AM metal powders down to individual particles by using high-resolution synchrotron x-ray computed tomography. Empowered by the penetrative capability of high-energy x-ray, internal porosity and contamination within as-atomized metal powders from high-entropy alloys to nickel-based superalloys were evaluated. Additionally, the newly-developed dispersion method enables the homogeneous separation of individual particles, and consequently, results in the implementation of 3D particle shape analysis. To resolve a major challenge of identification and quantification of satellite-feature particles in as-atomized AM metal powders, the satellite features were quantitated by modeling and analyzing the shape parameter of local thickness variance. Furthermore, the 3D analytical methods of particle assessment in this study can be applied to other materials systems like rock, food, and pharmaceutical particles, and provide insights for process optimization across powder metallurgy, concrete, food and pharmaceutical manufacturing, and AM industries.
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Series
IS-J 10731
Academic or Administrative Unit
Type
article
Comments
This is a manuscript of an article published as Xiong, Lianghua, Andrew Chihpin Chuang, Jonova Thomas, Timothy Prost, Emma White, Iver Anderson, and Dileep Singh. "Defect and satellite characteristics of additive manufacturing metal powders." Advanced Powder Technology 33, no. 3 (2022): 103486.
DOI: 10.1016/j.apt.2022.103486.
Copyright 2022 The Society of Powder Technology Japan.
Posted with permission.
DOE Contract Number(s): AC02-06CH11357; AC02-07CH11358.