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Preparation of additive manufacturing powder by external field–enabled: a comparative assessment

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Abstract

As an important raw material for additive manufacturing (AM), the performance of powder is one of the key factors affecting the final product. Although, existing preparation methods have been maturely applied to AM powder. However, conventional methods cannot meet the urgent needs of AM for high-performance powder. Especially in terms of powder sphericity, particle size distribution, and purity, it is difficult to obtain powder with balanced performance by conventional methods. In view of this, external field–enabled atomization is an effective alternative method. In recent years, a large number of studies have explored the application of external field–enabled atomization in powder preparation. These studies demonstrate the great potential of external field–enabled atomization technology represented by electrospray and ultrasonic atomization for the preparation of high-performance AM powder. However, there is still a lack of systematic discussion to establish the relationship between external field–enabled atomization and AM powder. Therefore, this paper makes a comprehensive and systematic review of the research progress in the field of powder preparation by external field–enabled atomization. Firstly, the influence of powder properties on parts is analyzed from the perspective of AM. Some conventional methods of powder preparation are introduced, and their shortcomings are pointed out. Secondly, the mechanism, equipment, and process parameters of external field–enabled atomization are comprehensively summarized. It is proved that external field–enabled atomization is applicable to the preparation of high-performance powder. Finally, the main challenges of external field–enabled atomization in the field of powder preparation are summarized.

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Abbreviations

AM :

Additive manufacturing

EIGA :

Electrode induction melting gas atomization

EBM :

Electron beam melting

E MQL :

Electrostatic minimum quantity lubrication

GMR :

Gas-to-melt mass flow rates ratio

MMA :

Methyl methacrylate

M QL :

Minimum quantity lubrication

PBF :

Powder bed fusion

PREP :

Plasma rotating electrode atomization

PA :

Plasma atomization

PLA :

Polylactic acid

PS :

Polystyrene

PA :

Polyamide

PP :

Polypropylene

PMMA :

Polymethyl methacrylate

SLM :

Selective laser melting

SLS :

Selective laser sintering

USWA :

Ultrasonic standing wave atomization

VIGA :

Vacuum induction melting gas atomization

VAE :

Vinyl acetate-ethylene copolymer emulsion

A e :

Amplitude threshold

d 50 :

Mean particle size

D l :

Diameter of melt stream flow

D e :

Electrode diameter

d p :

Droplet diameter

f :

Excitation frequency

G :

Flow rates of gas

K :

Electrical conductivity of the atomized liquid

K 1 :

A comprehensive parameter related to state of the melt stream and nozzle

K 2 :

A comprehensive parameter related to physical properties and process parameters of the alloy

L r :

Splitting limit of droplets

M :

Flow rates of molten metal

n :

Electrode rotation speed

P s :

Static pressure of liquid

P c :

Electrostatic expansion force

Q 0 :

The minimum flow value required to stabilize the cone jet mode

q R :

Maximum charge carried by the droplet

r :

Droplet radius

W :

Weber number

ε :

Dielectric constant of the liquid

σ :

Surface tension of liquids

\({\gamma }_{l}\) :

Surface tension of the liquid

\({\gamma }_{m}\) :

Surface tension of molten metal

ρ l :

Density of the liquid

ρ :

The density of melt droplets

λ :

Wavelength

η :

Viscosity of the liquid

η g :

Kinematic viscosities of gas

η m :

Kinematic viscosities of molten metal

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Funding

This work was supported by Liaoning Provincial Science and Technology Plan Project (Grant No. 2021JH2/10100012), Guangdong Major Project of Basic and Applied Basic Research (Grant No. 2021B0301030002), China Postdoctoral Science Foundation (Grant No. 2023M732826) and Liaoning University of Technology Doctoral research launch project (Grant No. XB2021002).

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Authors and Affiliations

  1. College of Mechanical Engineering and Automation, Liaoning University of Technology, Jinzhou, 121001, China

    Shuo Feng, Dongzhou Jia, Xiangqing Kong & Qi Gao

  2. Songshan Lake Material Laboratory, Dongguan, 523808, China

    Ying Fu

  3. School of Materials Science and Engineering, Xi`an University of Technology, Xi’an, 710048, China

    Zhenlin Lv

  4. Shandong Dongyu Construction Machinery Co, Jining, 272000, China

    Erjun Zeng

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  1. Shuo Feng
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  2. Dongzhou Jia
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  4. Xiangqing Kong
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  6. Erjun Zeng
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  7. Qi Gao
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All authors contributed to the study conception and design. Material preparation, data collection, and analysis were performed by Shuo Feng and Dongzhou Jia. The first draft of the manuscript was written by Shuo Feng, and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Dongzhou Jia.

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Feng, S., Jia, D., Fu, Y. et al. Preparation of additive manufacturing powder by external field–enabled: a comparative assessment. Int J Adv Manuf Technol 131, 3239–3265 (2024). https://doi.org/10.1007/s00170-023-12073-x

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