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Studies of the process variables in the inert gas atomization in the production of metal powders for DED - Direct Energy Deposition and PBD - Powder Bed Deposition

Grant number: 19/13715-4
Support Opportunities:Scholarships in Brazil - Post-Doctoral
Effective date (Start): September 01, 2019
Effective date (End): August 31, 2023
Field of knowledge:Engineering - Materials and Metallurgical Engineering
Principal Investigator:Mário Boccalini Júnior
Grantee:Flávia Costa da Silva
Host Institution: Escola de Engenharia de São Carlos (EESC). Universidade de São Paulo (USP). São Carlos , SP, Brazil
Associated research grant:16/11309-0 - The study, development and application of a hybrid process: Additive Manufacturing (AM) plus High Speed Machining/Grinding (HSM/G), AP.TEM


Among the new and major current challenges for manufacturing is economic and sustainable production. Additive Manufacturing (AM), capable of producing flexibility, total automation and sustainability, comes with a strong tendency to at least partially replace traditional casting, forging and machining processes. This technology was addressed in a workshop at the IPT in 2015 with the presence of directors, researchers and representatives of industry and development agencies (FAPESP).Given the relevance of the topic, it was suggested that the institutions involved with AM in the state of São Paulo meet to align efforts in the development of this new and innovative Manufacturing technology. Having assembled the team and assembled this proposal, in several meetings, it was verified that the future developments of this technology are, however, marked by several technological challenges, some of these treaties in this project. The surface finish of the parts obtained by AM is one of them, since it may not meet some high performance applications, requiring the use of subtractive processes, such as High Speed Machining/Grinding (HSM/G), characterizing a new class called Hybrid Processes (PrH). Other challenges that appear are the control over the metallurgical quality of the parts produced and the sobremetal needed for HSM/G machining. For this it is necessary to control the quality of the powder and the process parameters; both objects of study in this project. In terms of MA, two processes will be treated in a particular way in this study: Powder Bed Deposition-PBD and Direct Energy Deposition-DED. The first one tries to cast sequential layers of the metal bed with the use of laser and the second involves the concomitant use of the laser and the powder injected on the surface of the piece.Finally, the project intends to organize the researches for the execution of two products particularly important for the productive sector: tools for injection molding of thermoplastics and turbine blades for power generation, both obtained by the use of PrH. In addition to promoting scientific advancement and resource formation in this important and innovative area of manufacturing engineering, the project intends to advance the manufacture of real parts, which have a strong innovative character. Annual Workshops, involving the Project team and the productive sector, are among the expected targets, as well as patent applications for possible new processes, procedures and products. (AU)

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Scientific publications
(References retrieved automatically from Web of Science and SciELO through information on FAPESP grants and their corresponding numbers as mentioned in the publications by the authors)
FLÁVIA COSTA DA SILVA; MOYSÉS LEITE DE LIMA; GIOVANNA FIOCCO COLOMBO. Evaluation of a Mathematical Model Based on Lubanska Equation to Predict Particle Size for Close-Coupled Gas Atomization of 316L Stainless Steel. MATERIALS RESEARCH-IBERO-AMERICAN JOURNAL OF MATERIALS, v. 25, . (19/13715-4)

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