Correlation between particle size, secondary dendrite arm spacing, and local cooling rate in gas-atomized stainless steel powders for additive manufacturing

IF 4.5 2区工程技术 Q2 ENGINEERING, CHEMICAL

Powder Technology Pub Date : 2025-05-06 DOI:10.1016/j.powtec.2025.121096

Matheus Roberto Bellé, Anastasiia Sherstneva, Michael Hauser, Marco Wendler, Olena Volkova

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引用次数: 0

Abstract

Additive manufacturing (AM) demands metallic powders with controlled microstructure and morphology to ensure high-performance components, especially in processes like Laser Powder Bed Fusion (PBF-LB). Gas atomization techniques such as Vacuum Inert Gas Atomization (VIGA) and Electrode Inert Gas Atomization (EIGA) are widely employed for producing stainless steel powders tailored for AM applications. In this study, the solidification behavior of such powders is investigated by analyzing the secondary dendrite arm spacing (SDAS) as a function of particle size (15–170 μm). SDAS is used as a microstructural indicator to estimate local cooling rates during atomization. Experimental results reveal that SDAS increases linearly for particles ≤100 μm and exponentially for larger particles, independent of steel composition, atomization gas, or method. Derived cooling rates, ranging from 10⁴ to 10⁷ K s⁻¹, closely align with predictions from dimensionless criteria, affirming the relevance of such models under rapid solidification. Conversely, regressions developed for slower cooling conditions underestimate these values, emphasizing the need for high-fidelity models in atomization contexts. Notably, fine powders (< 25 μm) showed evidence of metastable δ-ferrite formation due to ultrafast cooling, as confirmed by magnetic saturation and XRD analyses. This work strengthens the predictive control of powder solidification behavior, aiding in the design of high-performance AM components.

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增材制造用气雾化不锈钢粉末中粒径、二次枝晶臂间距和局部冷却速率的关系

增材制造（AM）要求金属粉末具有可控的微观结构和形态，以确保部件的高性能，特别是在激光粉末床融合（PBF-LB）等工艺中。气体雾化技术，如真空惰性气体雾化（vaga）和电极惰性气体雾化（EIGA）被广泛用于生产适合增材制造应用的不锈钢粉末。在本研究中，通过分析二次枝晶臂间距（SDAS）随粒径（15 ~ 170 μm）的变化规律，研究了该粉末的凝固行为。SDAS被用作微观结构指标来估计雾化过程中的局部冷却速率。实验结果表明，对于≤100 μm的颗粒，SDAS呈线性增长，而对于较大的颗粒，SDAS呈指数增长，与钢的成分、雾化气体或雾化方法无关。得到的冷却速率范围从104到107 K s−1，与无量纲标准的预测密切一致，确认了这些模型在快速凝固下的相关性。相反，在较慢冷却条件下开发的回归低估了这些值，强调了在雾化环境下对高保真模型的需求。值得注意的是，细粉末(<；经磁饱和分析和XRD分析证实，25 μm)材料在超快冷却下形成了亚稳态δ铁氧体。这项工作加强了粉末凝固行为的预测控制，有助于高性能增材制造部件的设计。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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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.