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Title: Specific Adaptation of Gas Atomization Processing for Al-Based Alloy Powder for Additive Manufacturing

Abstract

The initial three atomization attempts resulted in “freeze-outs” within the pour tubes in the pilot-scale system and yielded no powder. Re-evaluation of the alloy liquidus temperatures and melting characteristics, in collaboration with Alcoa, showed further superheat to be necessary to allow the liquid metal to flow through the pour tube to the atomization nozzle. A subsequent smaller run on the experimental atomization system verified these parameters and was successful, as were all successive runs on the larger pilot scale system. One alloy composition froze-out part way through the atomization on both pilot scale runs. SEM images showed needle formation and phase segregations within the microstructure. Analysis of the pour tube freeze-out microstructures showed that large needles formed within the pour tube during the atomization experiment, which eventually blocked the melt stream. Alcoa verified the needle formation in this alloy using theoretical modeling of phase solidification. Sufficient powder of this composition was still generated to allow powder characterization and additive manufacturing trials at Alcoa.

Authors:
 [1];  [2]
  1. Ames Lab., Ames, IA (United States)
  2. Alcoa, Inc, Pittsburgh, PA (United States)
Publication Date:
Research Org.:
Ames Laboratory (AMES), Ames, IA (United States)
Sponsoring Org.:
USDOE
OSTI Identifier:
1373366
Report Number(s):
CRADA-2014-03
DOE Contract Number:
AC02-07CH11358
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE

Citation Formats

Anderson, Iver, and Siemon, John. Specific Adaptation of Gas Atomization Processing for Al-Based Alloy Powder for Additive Manufacturing. United States: N. p., 2017. Web. doi:10.2172/1373366.
Anderson, Iver, & Siemon, John. Specific Adaptation of Gas Atomization Processing for Al-Based Alloy Powder for Additive Manufacturing. United States. doi:10.2172/1373366.
Anderson, Iver, and Siemon, John. Fri . "Specific Adaptation of Gas Atomization Processing for Al-Based Alloy Powder for Additive Manufacturing". United States. doi:10.2172/1373366. https://www.osti.gov/servlets/purl/1373366.
@article{osti_1373366,
title = {Specific Adaptation of Gas Atomization Processing for Al-Based Alloy Powder for Additive Manufacturing},
author = {Anderson, Iver and Siemon, John},
abstractNote = {The initial three atomization attempts resulted in “freeze-outs” within the pour tubes in the pilot-scale system and yielded no powder. Re-evaluation of the alloy liquidus temperatures and melting characteristics, in collaboration with Alcoa, showed further superheat to be necessary to allow the liquid metal to flow through the pour tube to the atomization nozzle. A subsequent smaller run on the experimental atomization system verified these parameters and was successful, as were all successive runs on the larger pilot scale system. One alloy composition froze-out part way through the atomization on both pilot scale runs. SEM images showed needle formation and phase segregations within the microstructure. Analysis of the pour tube freeze-out microstructures showed that large needles formed within the pour tube during the atomization experiment, which eventually blocked the melt stream. Alcoa verified the needle formation in this alloy using theoretical modeling of phase solidification. Sufficient powder of this composition was still generated to allow powder characterization and additive manufacturing trials at Alcoa.},
doi = {10.2172/1373366},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Fri Jun 30 00:00:00 EDT 2017},
month = {Fri Jun 30 00:00:00 EDT 2017}
}

Technical Report:

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