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Investigation of Mechanical Properties of Parts Fabricated with Gas- and Water-Atomized 304L Stainless Steel Powder in the Laser Powder Bed Fusion Process

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Abstract

The use of gas-atomized powder as the feedstock material for the laser powder bed fusion (LPBF) process is common in the additive manufacturing (AM) community. Although gas-atomization produces powder with high sphericity, its relatively expensive production cost is a downside for application in AM processes. Water atomization of powder may overcome this limitation due to its low cost relative to the gas-atomization process. In this work, gas- and water-atomized 304L stainless steel powders were morphologically characterized through scanning electron microscopy (SEM). The water-atomized powder had a wider particle size distribution and exhibited less sphericity. Measuring powder flowability using the Revolution Powder Analyzer (RPA) indicated that the water-atomized powder had less flowability than the gas-atomized powder. Through examining the mechanical properties of LPBF fabricated parts using tensile tests, the gas-atomized powder had significantly higher yield tensile strength and elongation than the water-atomized powder; however, their ultimate tensile strengths were not significantly different.

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Acknowledgements

This work was funded by Honeywell Federal Manufacturing & Technologies under Contract No. DE-NA0002839 with the U.S. Department of Energy. The United States Government retains, and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a nonexclusive, paid up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes.

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Authors and Affiliations

  1. Department of Mechanical and Aerospace Engineering, Missouri University of Science and Technology, Rolla, MO, 65409, USA

    M. Hossein Sehhat & Ming C. Leu

  2. Los Alamos National Laboratory, Los Alamos, NM, 87545, USA

    Austin T. Sutton

  3. Department of Mechanical Engineering, National Cheng Kung University, Tainan, Taiwan

    Chia-Hung Hung

  4. Department of Materials Science and Engineering, Missouri University of Science and Technology, Rolla, MO, 65409, USA

    Joseph W. Newkirk

Authors
  1. M. Hossein Sehhat
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  2. Austin T. Sutton
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Correspondence to M. Hossein Sehhat.

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Sehhat, M.H., Sutton, A.T., Hung, CH. et al. Investigation of Mechanical Properties of Parts Fabricated with Gas- and Water-Atomized 304L Stainless Steel Powder in the Laser Powder Bed Fusion Process. JOM 74, 1088–1095 (2022). https://doi.org/10.1007/s11837-021-05029-7

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  • DOI: https://doi.org/10.1007/s11837-021-05029-7

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