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Metal powder as feedstock for laser-based additive manufacturing: From production to powder modification

Full text
Author(s):
Mathias, Laura E. T. ; Pinotti, Vitor E. ; Batistao, Bruna F. ; Rojas-Arias, Nicolas ; Figueira, Gustavo ; Andreoli, Angelo F. ; Gargarella, Piter
Total Authors: 7
Document type: Journal article
Source: Journal of Materials Research; v. 39, n. 1, p. 11-pg., 2023-12-29.
Abstract

Laser powder bed fusion (L-PBF) and direct laser deposition (DLD) are the two main processes currently used in the additive manufacturing (AM) of metals. For both methods, metal powders are used as feedstock, and they must present specific physical and chemical properties to ensure optimal processing and reliable and reproducible printing results. Particle morphology, size distribution, and flowability, among other factors, depend on the powder production process and directly influence the processing parameters and physical characteristics of the parts built by AM. This systematic review presents different concepts involving L-PBF and DLD manufacturing and the application of metal powders. The methods used to produce and characterize metal powders and the modification techniques to improve their processability by AM are detailed and discussed. Environmental and health risks are also presented, and safety measures that must be considered while handling metal powders. Some key topics requiring attention for further development are highlighted. (AU)

FAPESP's process: 20/09544-7 - Surface functionalization of AA2017 powder for additive manufacturing
Grantee:Bruna Fernanda Batistão
Support Opportunities: Scholarships in Brazil - Doctorate
FAPESP's process: 21/12056-7 - Soft magnetic composites produced by additive manufacturing
Grantee:Angelo Fernandes Andreoli
Support Opportunities: Scholarships in Brazil - Post-Doctoral
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Grantee:Laura Emi Tavoni Mathias
Support Opportunities: Scholarships in Brazil - Master
FAPESP's process: 20/08145-1 - Gas atomization of 2017 aluminum alloy
Grantee:Vitor Eduardo Pinotti
Support Opportunities: Scholarships in Brazil - Master
FAPESP's process: 20/01426-5 - Effect of processing parameters on microstruture and mechanical properties of aluminum alloys obtained by additive manufacturing
Grantee:Nicolás Rojas Arias
Support Opportunities: Scholarships in Brazil - Doctorate (Direct)
FAPESP's process: 17/27031-4 - Effect of process parameters on the metallurgical characteristics of additive-manufactured alloys
Grantee:Piter Gargarella
Support Opportunities: Research Grants - Young Investigators Grants
FAPESP's process: 19/01829-5 - Additive manufacturing by selective laser melting of stainless steel 316L with boron additions: evaluation of corrosion and wear properties
Grantee:Gustavo Figueira
Support Opportunities: Scholarships in Brazil - Doctorate