[SIS2] Novel processing strategies for Beam Based AM

[14B-SIS2-01] Keynote: Challenges for Additive Manufacturing of Nanoparticle-Infused Pre-Alloyed Water-Atomized Iron Powder

*J.-S. Lee¹, T. Im¹, B. V. Hooreweder², J.-K. Kim¹, C. S. Lee¹ (1.Hanyang University, Korea, 2.KU Leuven, Belgium)

Keywords:Pre-alloyed water-atomized iron powder, Additive manufacturing, Flowability, Microstructure, Tensile property

This presentation reports the development of nanoparticle-infused pre-alloyed water atomized (WA) iron powder (Fe-1.5Cu-1.75Ni-0.5Mo) for application in LPBF-based additive manufacturing (AM). First, the presentation focuses on powder manufacturing via nanopowder process in terms of chemical homogeneity and related properties of pre-alloyed powders. The second part introduces a case study on AM applications of pre-alloyed powders. Pre-alloyed powders were found to have a uniform distribution of nano-alloying elements placed into the concavities of the powder surface. These morphological changes effectively improved the flow- and packing properties. AM application investigations showed that a maximum relative density of 99.67% was achieved at an energy density of 108 J/mm³, accompanied by excellent mechanical and chemical homogeneity. The zigzag scanning method is advantageous for AM processes with uniform microstructure and stable tensile properties. It is concluded that nanoparticle-infused pre-alloyed WA iron powders provide a cost-effective alternative to gas atomized powders in AM applications.