Controlling factors determining flowability of powders for additive manufacturing: A combined experimental and simulation study

Yufan Zhao, Yujie Cui, Yusaku Hasebe, Huakang Bian, Kenta Yamanaka, Kenta Aoyagi, Takehito Hagisawa, Akihiko Chiba

Research output: Contribution to journalArticlepeer-review

Abstract

Powder flowability affects dynamic powder behavior during additive manufacturing and varies depending on particle size distribution, particle morphology, and surface features. In this study, Inconel 718 alloy powders were prepared by gas atomization (GA), plasma atomization (PA), and plasma rotating electrode process (PREP). The flowability was experimentally evaluated by the avalanche angle. With the help of numerical simulations, the individual effects of particle size distribution, particle morphology, and particle surface features on flowability were analyzed. The results showed that the PREP powder possessed the best flowability among the three powders. The PSDs were slightly different, but these differences had almost no effect on their flowability. Nevertheless, the excellent flowability of the PREP powder was due to the high particle sphericity and the thin surface oxide film. If the environmental factors are well controlled during the handling, PREP has a natural advantage over GA and PA in terms of flowability.

Original languageEnglish
Pages (from-to)482-493
Number of pages12
JournalPowder Technology
Volume393
DOIs
Publication statusPublished - 2021 Nov

Keywords

  • Discrete element method
  • Gas atomization
  • Inconel 718
  • Plasma atomization
  • Plasma rotating electrode process
  • Powder-based additive manufacturing

ASJC Scopus subject areas

  • Chemical Engineering(all)

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