Variations in GARS powder microstructure as a function of powder chemistry and particle size

deJong, Matthew; Tiarks, Jordan; Anderson, Iver; Parish, Chad; Forrester, Jennifer; Lapidus, Saul; Horn, Timothy; Kaoumi, Djamel

doi:10.1016/j.powtec.2025.120734

Variations in GARS powder microstructure as a function of powder chemistry and particle size

Journal Article · Sat Feb 01 00:00:00 EST 2025 · Powder Technology

DOI:https://doi.org/10.1016/j.powtec.2025.120734· OSTI ID:2558000

deJong, Matthew ^[1]; Tiarks, Jordan ^[2]; Anderson, Iver ^[2]; Parish, Chad ^[3]; Forrester, Jennifer ^[4]; Lapidus, Saul ^[1]; Horn, Timothy ^[1]; Kaoumi, Djamel ^[1]

North Carolina State University, Raleigh, NC (United States)
Ames Laboratory (AMES), Ames, IA (United States)
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
Argonne National Laboratory (ANL), Argonne, IL (United States). Advanced Photon Source (APS)

The properties of metal produced through powder metallurgy depends on the feedstock used. Powders produced via gas atomization reaction synthesis (GARS) are used to produce oxide dispersion strengthened alloys. The desired powder size range can vary for each consolidation technique. However, powder microstructure also can vary with powder particle size, which in turn can impact the microstructure and properties of the consolidated parts. In this study, GARS powders are characterized via inductively coupled plasma mass spectroscopy, inert gas fusion, and high-resolution x-ray diffraction to determine variations in elemental and phase compositions. Transmission electron microscopy was used to understand microstructure variations as a function of chemistry and size. Across the three batches tested intermetallic content was 0.73–1.35 wt% in the 0-20 μm powder batch and increased to 2.46–3.80 wt% in the coarse 45-106 μm batch. Across all batches, volume percent of surface oxidation decreased with powder diameter, with volume percents within the range of 0.75–1.2 % across 10 μm powder particles, and below 0.4 % across coarse powder particles approximately 100 μm in diameter. These observations were supported by inert gas fusion measurements. However, the oxide layer was thicker in coarse powder particles due to a slower cooling rate. Increasing oxygen content in atomization gas to 2000 ppm and adding yttrium increased both the surface oxidation content and yttrium intermetallic content. Lastly, intermetallic phases within the powder coarsened with powder size. Intermetallic morphology changed from fine spherical intermetallic and columnar dendritic growth to a cellular structure with finer spherical intermetallic, to coarse irregular intermetallic and intermetallic along grain boundaries as a result of slower cooling rate and solidification rate in coarse powder particles. Furthermore, the addition of zirconium does not appear to significantly change intermetallic morphology, but the composition changed from a Y-Fe rich intermetallic to a Y-Zr-Fe intermetallic.

View Accepted Manuscript (DOE)

Research Organization:: Ames Laboratory (AMES), Ames, IA (United States); North Carolina State University, Raleigh, NC (United States)

Sponsoring Organization:: USDOE National Nuclear Security Administration (NNSA), Office of Defense Nuclear Nonproliferation

Grant/Contract Number:: AC02-07CH11358; NA0003996

OSTI ID:: 2558000

Alternate ID(s):: OSTI ID: 2545900

Report Number(s):: AL-J--750

Journal Information:: Powder Technology, Journal Name: Powder Technology Vol. 455; ISSN 0032-5910

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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