Study of the influence of particle size distribution and moisture on the flowability of aluminum alloy powder through numerical modeling

• Grant number: 22/15683-5
• Support Opportunities: Scholarships in Brazil - Scientific Initiation
• Start date: June 01, 2023
• End date: May 31, 2025
• Field of knowledge: Engineering - Materials and Metallurgical Engineering - Physical Metallurgy
• Principal Investigator: Piter Gargarella
• Grantee: Leticia Viana Machado da Silva
• 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

The additive manufacturing method most used for metals is Laser Powder Bed Fusion (LPBF). In this process, a thin layer of metallic powder is placed on a substrate. The layer is then selectively melted by a laser beam, following a pre-defined model of the part. By repeating this process, complex shape particles with customized density can be obtained layer by layer. One of the main characteristics that the powder must have to be used in this process is good flowability to flow through the equipment piping and form a homogeneous layer without defects. Aluminum alloy powders are known to have lower flowability when compared to powders from other alloys, such as steels and titanium-based alloys. To increase flowability, a coarser particle size distribution is generally used and the powder is dried. This work aims to understand the reasons for the low flowability of aluminum alloy powder through numerical simulation. The YADE software will be used to simulate the flowability of Al-Fe-Cr-Ti aluminum alloy powder in different size ranges and humidity conditions. The results will be compared with the flowability measured using a Carney funnel. It is expected to obtain a better understanding of the effect of factors such as size and moisture distribution on the powder flow of aluminum alloys.