Stereologically corrected particle size distributions for polymer-mounted additive manufacturing powders

IF 4.5 2区工程技术 Q2 ENGINEERING, CHEMICAL

Powder Technology Pub Date : 2024-06-18 DOI:10.1016/j.powtec.2024.120022

Courtney Gallagher , Emmett Kerr , Shaun McFadden

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Abstract

Well-defined particle size distributions are required for good flowability and powder packing properties of additive manufacturing powders. Mounting powders within a polymer and using standard metallurgical preparation techniques to cross-section and prepare powder particles for optical analysis allows for simple characterisation processes. However, measured diameters of cross-sectioned particles are typically underestimates of actual particle diameters and hence require stereological correction. The effectiveness of three stereological corrections are investigated in this work, namely the Scheil-Schwartz-Saltykov method, the Goldsmith-Cruz-Orive method and a Finite Difference Method. These methods are investigated against plasma-atomised, gas-atomised and ultrasonically processed Ti-6Al-4V powders. The corrected outputs are compared to laser size diffraction, benchmark data for each powder. Although all three stereological corrections produce improved estimations of the particle size distributions, the Finite Difference Method is recommended producing cumulative mean absolute error values of 2.4%, 3.1% and 7.5% for the plasma-atomised, gas-atomised and ultrasonically processed powders respectively.

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聚合物固定添加剂制造粉末的立体校正粒度分布

要使增材制造粉末具有良好的流动性和粉末填料特性，就必须有明确的粒度分布。将粉末装入聚合物中，使用标准冶金制备技术对粉末颗粒进行横截面制备并进行光学分析，可实现简单的表征过程。然而，横截面颗粒的测量直径通常会低估实际颗粒直径，因此需要进行立体修正。本研究调查了三种立体修正方法的有效性，即 Scheil-Schwartz-Saltykov 方法、Goldsmith-Cruz-Orive 方法和有限差分法。这些方法针对等离子体雾化、气体雾化和超声波处理的 Ti-6Al-4V 粉末进行了研究。将校正后的输出结果与激光粒度衍射、每种粉末的基准数据进行比较。尽管所有三种立体校正方法都能改进对粒度分布的估计，但对于等离子体化、气体原子化和超声波处理的粉末，建议采用有限差分法，其累计平均绝对误差值分别为 2.4%、3.1% 和 7.5%。

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来源期刊

Powder Technology 工程技术-工程：化工

CiteScore

9.90

自引率

15.40%

发文量

1047

审稿时长

46 days

期刊介绍： Powder Technology is an International Journal on the Science and Technology of Wet and Dry Particulate Systems. Powder Technology publishes papers on all aspects of the formation of particles and their characterisation and on the study of systems containing particulate solids. No limitation is imposed on the size of the particles, which may range from nanometre scale, as in pigments or aerosols, to that of mined or quarried materials. The following list of topics is not intended to be comprehensive, but rather to indicate typical subjects which fall within the scope of the journal's interests: Formation and synthesis of particles by precipitation and other methods. Modification of particles by agglomeration, coating, comminution and attrition. Characterisation of the size, shape, surface area, pore structure and strength of particles and agglomerates (including the origins and effects of inter particle forces). Packing, failure, flow and permeability of assemblies of particles. Particle-particle interactions and suspension rheology. Handling and processing operations such as slurry flow, fluidization, pneumatic conveying. Interactions between particles and their environment, including delivery of particulate products to the body. Applications of particle technology in production of pharmaceuticals, chemicals, foods, pigments, structural, and functional materials and in environmental and energy related matters. For materials-oriented contributions we are looking for articles revealing the effect of particle/powder characteristics (size, morphology and composition, in that order) on material performance or functionality and, ideally, comparison to any industrial standard.