Papers

Additive manufacturing of a high-performance aluminum alloy from cold mechanically derived non-spherical powder

Martin, J.H., Barnes, J.E., Rogers, K.A. et al. Additive manufacturing of a high-performance aluminum alloy from cold mechanically derived non-spherical powder. Commun Mater 4, 39 (2023). https://doi.org/10.1038/s43246-023-00365-4

The paper Additive manufacturing of a high-performance aluminum alloy from cold mechanically derived non-spherical powder” from Martin, J.H., Barnes, J.E., Rogers, K.A. et al., discusses a novel approach to metal additive manufacturing (AM) that addresses current limitations in material availability and production speed. Traditionally, AM relies on spherical powder feedstock produced by gas atomization at large, centralized facilities, which leads to long lead times and limited material options. The paper introduces a new "on-demand" powder production technology that generates non-spherical powders through a cold mechanical process. This method is both efficient and capable of producing materials with properties equivalent to wrought metals, which are highly desirable in manufacturing.

The researchers conducted powder characterization using the Granudrum, a device where powder is photographed and analyzed in a rotating drum. This technique allows for the assessment of the cohesive index and angle of repose, key indicators of powder flow characteristics, and not only particle shape and size obtained with a Particle Size Distribution (PSD) test. The results of these analyses were crucial in comparing the flow characteristics and mechanical properties of the non-spherical powders produced by the new process to those of conventional gas-atomized powders.

The study demonstrates that despite differences in powder shape, the new process achieves similar mechanical properties to wrought materials. This breakthrough has significant implications for expanding the range of materials available for AM, particularly benefiting industries such as automotive, which have yet to fully leverage AM technology due to material limitations. The findings suggest that this new powder production method could enhance supply chain flexibility and foster the development of new alloys for various AM applications.

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