Gas-atomized Fe–24Cr–8Al–0.5Y (wt.%) powder was used as a feedstock in a laser powder bed fusion process with nitrogen atmosphere. Formation of Al–Y–O-enriched nanoparticles with diameters of 10–100 nm implied in-situ precipitation of Al–Y–O-enriched nanoparticles within the ferritic matrix developing an oxide dispersion strengthened FeCrAl alloy without any mechanical alloying. Thermodynamics...
The recyclability of 316L stainless steel powder in the binder jetting process has been determined. The powder characterization results demonstrated a 22% increase in the number of coarse particles (> 30 µm) and an 18.2% reduction in the number of small particles (< 10 µm) after recycling up to 16 times. A...
High Entropy Alloys (HEA) exhibit unusual properties and are gaining interest as new materials for challenging applications in the aerospace, hypersonic and medical fields. The application of HEAs have been limited by the development of powder production at scale. A recently developed process of plasma spheroidization by 6K, inc. has...
The role of volumetric energy density on the microstructural evolution, texture and mechanical properties of 304L stainless steel parts additively manufactured via selective laser melting process is investigated. 304L is chosen because it is a potential candidate to be used as a matrix in a metal matrix composite with nanoparticles...
Water-atomized and gas-atomized 17-4 PH stainless steel powder were used as feedstock in selective laser melting process. Gas atomized powder revealed single martensitic phase after printing and heat treatment independent of energy density. As-printed water atomized powder contained dual martensitic and austenitic phase regardless of energy density. The H900 heat...
The aim of this work was to assess the viability of duplex stainless steel 2205 components built via selective laser melting for seawater applications. First, a comprehensive additive manufacturing assessment was done. The duplex stainless steel 2205 components were selectively laser melted from gas atomized powder (D90 <45m) using a...
This study investigates the microstructure and mechanical properties of an austenitic Oxide Dispersion Strengthened (ODS) steel produced by the Laser Directed Energy Deposition (LDED) process using powder feedstock atomized with elemental yttrium. The Microstructure of the samples was characterized by electron microscopy, and mechanical properties were measured using a tensile...
A nickel-based Hastelloy C22 powder with a nominal composition of Ni-21.30Cr-13.36Mo-1.92Co-2.94W-3.85Fe-0.23Mn-0.3V(wt%) and particle size distribution of D₁₀=23.8±0.3 μm, D₅₀=37.5±0.2μm, and D₉₀=59.3±1.1 μm was gas atomized to be used as a feedstock in Laser Powder Bed Fusion (LPBF). In this study, laser power and scanning speed were optimized to manufacture specimens...
Oxide dispersion strengthened (ODS) alloys exhibit superior mechanical properties due to the presence of nano-sized thermally stable oxide particles. However, manufacturing of ODS alloys is very complex and composed of numerous time consuming steps such as mechanical alloying, which is one of the main barriers toward the widespread application of...