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1 Journal of Achievements in Materials and Manufacturing Engineering

1 2023

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Comparison of ultrasonic and other atomization methods in metal powder production

Bałasz B., Bielecki M., Gulbiński W., Słoboda Ł.

Journal of Achievements in Materials and Manufacturing Engineering

2023

Vol. 116, nr 1

11--24

Purpose: Additive manufacturing (AM) research needs new alloys to grow and offer new functionalities. This paper presents a novel powder production method by means of ultrasonic atomisation (UA). Powders for AM can be obtained from gas atomisation (GA) and a comparative study of UA- vs GA-made powders were carried out. To UA explain the pros & cons more clearly, a summary of the processes was added, along with the analysis of the droplet formation physics. Design/methodology/approach: Ultrasonic atomization (UA) with melting raw material by an electric arc. Characterisation of the powders: particle size distribution (PSD), density, and flowability were carried out. Other parameters, such as microstructure, deviation in the chemical composition and powder surface morphology, were also investigated. Findings: The results showed that the UA powder has a finer average particle size with a narrower statistical distribution of particles than those made by the GA method. Because the UA powder has a higher sphericity and lower porosity, Generally, UA offers better-quality powders in terms of properties such as higher tap density, better flowability and low oxygen content. Research limitations/implications: As an example of semi-industrial scale application of the UA system, the Ti6Al4V and TiAl powders were produced after remelting the wire. The UA system is commercially available for processing any metallic material. Practical implications: The test campaign results showed that the Ti6Al4V powder produced by the ultrasonic atomisation has a similar or better quality as those available from large-scale gas atomisation plants. Originality/value: The new method of UA powder production was analysed in terms of key powder parameters. The properties of the titanium-based powder produced this way were analysed with a view to future applications.