Investigating particle morphology, quality, flowability and performance of abrasive-grinding based powders for directed energy deposition

Dhami, HS and Viswanathan, K (2024) Investigating particle morphology, quality, flowability and performance of abrasive-grinding based powders for directed energy deposition. In: Powder Technology, 437 .

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Abstract

Laser based metal additive manufacturing relies on the fusion of metallic powders to produce dense near-net shape parts. While these powders have conventionally been produced using atomization-derived techniques, the attendant high costs and inherent material inflexibility have spurred recent research into alternative low cost powder production routes. In this work, we investigate an abrasive-grinding based process for producing spherical metal powder particles in steels. We present morphological investigations, coupled with characterization of particle surface quality, using electron microscopy, ion beam milling, spectroscopic techniques, and X-ray diffraction. To minimize the occurrence of surface oxide layers during the grinding process, we study oxide scale reduction kinetics using electrical current measurements in a 1 hydrogen environment. We also assess the flowability of the produced powders through standard angle of repose and flow rate measurements, to evaluate their potential use as feedstock. Finally, we explicitly demonstrate the usability of these abrasive-grinding based powders by printing standard multi-layer structures using a directed energy deposition configuration. Deposition quality is quantified using microstructure/phase analysis and micro/nano hardness measurements. Our results show that these powders hold promise as an alternative feedstock material for additive manufacturing applications. © 2024

Item Type:	Journal Article
Publication:	Powder Technology
Publisher:	Elsevier B.V.
Additional Information:	The copyright for this article belongs to Elsevier B.V.
Keywords:	3D printing; Additives; Deposition; Feedstocks; Flow rate; Ion beams; Morphology; Powder metals; Quality control, Additive manufacturing; Directed energy; Directed energy deposition; Energy depositions; Flowability; Particle morphologies; Particle performance; Particle quality; Powder processing; Reduction kinetics, Grinding (machining), abrasive-grinding based powder; analysis; angle of repose; Article; directed energy deposition; electric current; energy dispersive X ray spectroscopy; field emission scanning electron microscopy; flow rate; focused ion beam milling; laser power; layer overlap; morphology; particle morphology; particle size; phase analysis; physical parameters; powder; powder feed rate; powder flow; powder size distribution; procedures; reduction kinetics; structure analysis; three dimensional printing; traverse speed; Vickers microhardness; X ray diffraction
Department/Centre:	Division of Mechanical Sciences > Mechanical Engineering
Date Deposited:	22 May 2024 11:50
Last Modified:	22 May 2024 11:50
URI:	https://eprints.iisc.ac.in/id/eprint/84818

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