Effects of Particle Size Distribution with Efficient Packing on Powder Flowability and Selective Laser Melting Process

Young, Zachary; Qu, Minglei; Coday, Meelap Michael; Guo, Qilin; Hojjatzadeh, Seyed Mohammad H.; Escano, Luis I.; Fezzaa, Kamel; Chen, Lianyi

doi:10.3390/ma15030705

Effects of Particle Size Distribution with Efficient Packing on Powder Flowability and Selective Laser Melting Process

Journal Article · Mon Jan 17 23:00:00 EST 2022 · Materials

DOI:https://doi.org/10.3390/ma15030705· OSTI ID:1894949

Young, Zachary ^[1]; ^[2]; Coday, Meelap Michael ^[1]; ^[2]; ^[1]; Escano, Luis I. ^[2]; ^[3]; ^[1]

Missouri Univ. of Science and Technology, Rolla, MO (United States); Univ. of Wisconsin, Madison, WI (United States)
Univ. of Wisconsin, Madison, WI (United States)
Argonne National Lab. (ANL), Argonne, IL (United States). Advanced Photon Source (APS)

The powder bed-based additive manufacturing (AM) process contains uncertainties in the powder spreading process and powder bed quality, leading to problems in repeatability and quality of the additively manufactured parts. This work focuses on identifying the uncertainty induced by particle size distribution (PSD) on powder flowability and the laser melting process, using Ti6Al4V as a model material. The flowability test results show that the effect of PSDs on flowability is not linear, rather the PSDs near dense packing ratios cause significant reductions in flowability (indicated by the increase in the avalanche angle and break energy of the powders measured by a revolution powder analyzer). The effects of PSDs on the selective laser melting (SLM) process are identified by using in-situ high-speed X-ray imaging to observe the melt pool dynamics during the melting process. The results show that the powder beds made of powders with dense packing ratios exhibit larger build height during laser melting. The effects of PSD with efficient packing on powder flowability and selective laser melting process revealed in this work are important for understanding process uncertainties induced by feedstock powders and for designing mitigation approaches.

View Accepted Manuscript (DOE)

Research Organization:: Argonne National Laboratory (ANL), Argonne, IL (United States)

Sponsoring Organization:: USDOE Office of Science (SC), Basic Energy Sciences (BES). Scientific User Facilities Division; National Science Foundation (NSF)

Grant/Contract Number:: AC02-06CH11357

OSTI ID:: 1894949

Journal Information:: Materials, Journal Name: Materials Journal Issue: 3 Vol. 15; ISSN 1996-1944

Publisher:: MDPICopyright Statement

Country of Publication:: United States

Language:: English

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36 MATERIALS SCIENCE
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