Gas atomization of 2017 aluminum alloy

• Grant number: 20/08145-1
• Support Opportunities: Scholarships in Brazil - Master
• Start date: August 01, 2020
• End date: July 31, 2022
• Field of knowledge: Engineering - Materials and Metallurgical Engineering - Physical Metallurgy
• Principal Investigator: Piter Gargarella
• Grantee: Vitor Eduardo Pinotti
• Host Institution: Centro de Ciências Exatas e de Tecnologia (CCET). Universidade Federal de São Carlos (UFSCAR). São Carlos , SP, Brazil
• Associated research grant: 17/27031-4 - Effect of process parameters on the metallurgical characteristics of additive-manufactured alloys, AP.JP

Abstract

One of the several important parameters in the additive manufacturing method of Powder Bed Fusion is the powder used. The powder must have spherical morphology, Gaussian size distribution, with particles in the range of 15 to 45 microns and with the smallest amount of satellite particles possible. These characteristics are important to ensure good densification of the powder layer and also good flowability. However, the great challenge is to obtain the largest fraction possible of powders with these characteristics using gas atomization. This process is the most economical method to obtain metallic powder with these characteristics in large quantities. Recently, a PSI brand gas atomizer was installed at the Atomization and Coating Laboratory at DEMa/UFSCar. This atomizer allows the production of up to 10 kg of aluminum alloy powder. A detailed study is still needed on how the different parameters of this process affect the characteristics of aluminum alloy powders produced in this equipment. This master's project aims to evaluate the effect of the different parameters of the gas atomization process (atomization pressure, gas-metal ratio, atomization temperature, among others) on the characteristics of 2017 aluminum alloy powder. Powders will be produced in the gas atomizer at DEMa/UFSCar using different process parameters. The experiments will be carried out following a methodology based on Design of Experiment (DOE). The powders obtained will be sieved and the different granulometric ranges will have their morphology and satellites formation, roughness and flowability analyzed. The experimental data obtained will be investigated within the DOE methodology to assess the most important and appropriate parameters for the process. The results obtained will also be compared with predictions of mathematical models previously developed by the research group of DEMa/UFSCar. (AU)