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@article{faucris.203904817,
abstract = {Current requirements for metal powder in Additive Manufacturing via
Laser Beam Melting in powder bed (LBM) that ensure repeatably
homogeneous thin layers can be spread and LBM products with high
relative density ρrel can be built are high sphericity and
particle size distributions (PSD) with limited share of fine particles.
The most established LBM powder production method today is delicate and
costly inert gas atomization. It yields highly spherical particles with
continuous particle size distributions, but two thirds of the atomized
powder exceed established LBM size ranges. A novel process route to
improve flowability of cohesive metal powders is the coating of
micro-sized powder particles with small amounts of nanoparticles. In
this article, significant improvements in powder layer smoothness and ρrel
of LBM samples are shown by statistical analysis of physical
experiments on the example of Al-Si powders dry coated with 0.5 wt%
nanoparticular fumed silica SiOx. This setup was chosen
because Al is most prone to powder flowability issues in LBM and no new
chemical elements are added to the alloy from dry coated SiOx.
Particle shape is varied from spherical over ovoidal to irregular using
powder atomized with Ar, N and air. Effects of variations of PSD and
LBM parameters on ρrel, defect types, microstructure and hardness using powders with and without SiOx are investigated. Because ρrel
are skewed towards 100%, ANOVA on ranks is the applicable statistical
method. Since the principle of using nanoparticles as spacers between
microparticles is based on geometry, it is transferrable to other
material systems. This may help for example to increase ρrel
of LBM metal matrix composites prepared by mechanical alloying as
non-spherical particles with considerable amounts of fine particles. The
use of larger percentages of atomized powders in LBM can increase
resource efficienc},
author = {Karg, Michael and Munk, Alexander and Ahuja, Bhrigu and Backer, Manuel Veit and Schmitt, Jana Petra and Stengel, Christopher and Kuryntsev, Sergey Vyacheslavovich and Schmidt, Michael},
doi = {10.1016/j.jmatprotec.2018.08.045},
faupublication = {yes},
journal = {Journal of Materials Processing Technology},
keywords = {Selective Laser Melting™; AlSi10Mg; Particle size distribution; Particle morphology; Fumed silica nanoparticles; Powder layer spreading; ANOVA on ranks},
pages = {155-171},
peerreviewed = {Yes},
title = {{Expanding} particle size distribution and morphology of aluminium-silicon powders for {Laser} {Beam} {Melting} by dry coating with silica nanoparticles},
volume = {264},
year = {2018}
}