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Advanced Powder Fabrication Techniques for Laser Powder Bed Fusion

Naoyuki Nomura^1,*, Mingqi Dong¹, Zhenxing Zhou¹, Weiwei Zhou¹

1 Department of Materials Processing, Graduate School of Engineering, Tohoku University, Sendai, 9808579, Miyagi, Japan

* Corresponding Author: Naoyuki Nomura. Email:

The International Conference on Computational & Experimental Engineering and Sciences 2024, 31(4), 1-1. https://doi.org/10.32604/icces.2024.012381

Abstract

Laser powder bed fusion (L-PBF) exhibits many technological opportunities for producing high-performance metallic parts with tailored architectures. However, fabrication of suitable composite powders possessing good flowability, controllable particle size and distribution is a currently prerequisite and main challenge. In this work, two novel techniques, namely freeze-dry pulsated orifice ejection method (FD-POEM) [1] and ultrafine bubble (UFB)-assisted heteroagglomeration [2], have been developed to fabricate uniform composite powders. By taking MoSiBTiC alloy powders as an example, the working principle of FD-POEM process was firstly illustrated. The spherical FD-POEM particles were consisted of typical mesh structures induced by the sublimation of ice crystals, benefiting to enhanced laser absorptivity. In addition, high-concentration, impurity-free nanoceramic/metal composite powders were fabricated using the negatively charged UFBs. Thanks to their bridging effect, individual ZrO₂ or Al₂O₃ nanoparticles up to ~10wt% were homogeneously decorated on the surface of Ti-6Al-4V powders. The nanoceramics were completely decomposed and dissolved into the matrix during L-PBF; thus, a unique Ti nanocomposite exhibiting a high tensile strength of 1.4GPa and an acceptable ductility of 8.1% was fabricated. This work offers new insight into the fabrication of unique L-PBF powders and the mechanical functionalization of metallic parts.

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Keywords

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