Spherical powders with good flowability and high stacking density are mandatory for powder bed additive manufacturing. Nevertheless, the preparation of spherical refractory tungsten and tungsten alloy powders is a for...Spherical powders with good flowability and high stacking density are mandatory for powder bed additive manufacturing. Nevertheless, the preparation of spherical refractory tungsten and tungsten alloy powders is a formidable task. In this paper, spherical refractory metal powders processed by high-energy stir ball milling and RF inductively coupled plasma were investigated. By utilizing the technical route, pure spherical tungsten powders were prepared successfully, the flowability increased from 10.7 s/50 g to 5.5 s/50 g and apparent density increased from 6.916 g cm-3 to 11.041 g cm-3. Alloying element tantalum can reduce the tendency to micro- crack during tungsten laser melting and rapid solidification process. Spherical W-6Ta （%wt） powders were prepared in this way, homogeneous dispersion of tantalum in a tungsten matrix occurred but a small amount of flake-like shape particles appeared after high-energy stir ball milling. The flake-like shape particles can hardly be spheroidized in subsequent RF inductively coupled plasma process, might result from the unique suspended state of flaky particles under complex electric and magnetic fields as well as plasma-particle heat exchange was different under various turbulence models. As a result, the flake-like shape particles cannot pass through the high-temperature area of thermal plasma torch and cannot be spheroidized properly.展开更多
The powder characteristics,such as particle size and geometry,play an important role in determining the quality of powder layer and parts fabricated with powder-based additive manufacturing processes.Previous research...The powder characteristics,such as particle size and geometry,play an important role in determining the quality of powder layer and parts fabricated with powder-based additive manufacturing processes.Previous research has found that spherical particles result in better powder flowability and spreadability.An attempt to improve particle sphericity is to process the powder using plasma spheroidization,where the particles heat up,melt,and reshape to spheres.Several research works have been conducted to study the plasma spheroidization process and understand particle-plasma reactions.Although researchers have turned to simulations to overcome the difficulty of experimental study of such reactions,they only characterized the powder particle size without evaluating the particle geometry.In this work,the plasma spheroidization process of copper powder was numerically and experimentally examined to assess the impact of plasma spheroidization on particle size and geometry.For the first time in the literature,a method of simulation was proposed to numerically quantify the particle geometry at each particle residence time.The results of simulation agreed well with those of experiments.展开更多
To control the morphology and particle size of dense spherical molybdenum powder prepared by radio frequency（RF） plasma from irregular molybdenum powder as a precursor, plasma process parameters were optimized in th...To control the morphology and particle size of dense spherical molybdenum powder prepared by radio frequency（RF） plasma from irregular molybdenum powder as a precursor, plasma process parameters were optimized in this paper. The effects of the carrier gas flow rate and molybdenum powder feeding rate on the shape and size of the final products were studied. The molybdenum powder morphology was examined using high-resolution scanning electron microscopy. The powder phases were analyzed by X-ray diffraction. The tap density and apparent density of the molybdenum powder were investigated using a Hall flow meter and a Scott volumeter. The optimal process parameters for the spherical molybdenum powder preparation are 50 g/min powder feeding rate and 0.6 m^3/h carrier gas rate. In addition, pure spherical molybdenum powder can be obtained from irregular powder, and the tap density is enhanced after plasma processing. The average size is reduced from 72 to 62 μm, and the tap density is increased from 2.7 to 6.2 g/cm^3. Therefore, RF plasma is a promising method for the preparation of high-density and high-purity spherical powders.展开更多
Arc plasma torch is an effective tool for spheroidization of metallic powders.However,as most conventional plasma torches were not specifically designed for plasma spheroidization,they may exhibit the disadvantages of...Arc plasma torch is an effective tool for spheroidization of metallic powders.However,as most conventional plasma torches were not specifically designed for plasma spheroidization,they may exhibit the disadvantages of the radial injection of powders,large fluctuations in the arc voltage,large gas flow rate,and disequilibrium between multiple plasma jets during the spheroidization process.Therefore,this paper presents a triple-cathode cascade plasma torch(TCCPT)for plasma spheroidization.Its structural design,including three cathodes,a common anode,and three sets of inter-electrodes,are detailed to ensure that powders can be inserted into the plasma jet by axial injection,the arc voltage fluctuations are easily maintained at a low level,and the plasma torches can work at a relatively small gas flow rate.Experimental results showed that the proposed TCCPT exhibits the following characteristics:(1)a relatively small arc voltage fluctuation within 5.3%;(2)a relatively high arc voltage of 75 V and low gas flow rate range of10-30 SLM;(3)easy to be maintained at the equilibrium state with the equilibrium index of the three plasma jets within 3.5 V.Furthermore,plasma spheroidization experiments of SUS304 stainless steel powers were carried out using the proposed TCCPT.Results verified that the proposed TCCPT is applicable and effective for the spheroidization of metallic powders with wide size distribution.展开更多
In order to prepare high quality Mo（Si,Al）2 feedstock characterized with C40 phase, higher Al doping amount andexcellent flowability, Mo（Si1-x,Alx）2 with different Al contents （x=0, 0.1, 0.2, 0.3, 0.4, 0.5） were...In order to prepare high quality Mo（Si,Al）2 feedstock characterized with C40 phase, higher Al doping amount andexcellent flowability, Mo（Si1-x,Alx）2 with different Al contents （x=0, 0.1, 0.2, 0.3, 0.4, 0.5） were synthesized by self-propagatinghigh-temperature synthesis first and Mo（Si0.6,Al0.4）2 was confirmed as the suitable material through X-ray diffraction analysis. Aseries of tests with different parameters of induction plasma spheroidization were applied to improving the flowability of feedstock.Mo（Si,Al）2 feedstock with excellent flowability （26.2 s/50 g） was prepared through adding hydrogen into sheath gas and decreasingthe powder feeding rate. The composition segregation occurred in the spheroidized powder after Al consumption and oxidation. Theinhomogeneous structure of the same particle was caused by the asymmetric heating and cooling when particle passed through theplasma jet.展开更多
An arc channel at atmospheric pressure tends to shrink generally. In this paper, a non-transferred DC arc plasma device with multiple cathode is introduced to produce a large area arc plasma at atmospheric pressure. T...An arc channel at atmospheric pressure tends to shrink generally. In this paper, a non-transferred DC arc plasma device with multiple cathode is introduced to produce a large area arc plasma at atmospheric pressure. This device is comprised of a 42-mm diameter tubular chamber, multiple cathode which is radially inserted into the chamber, and a tungsten anode with a nozzle in its center. In argon/helium atmosphere, a large area and circumferential homogenous diffuse arc plasma, which fills the entire cross section surrounded by the cathode tips, is observed. Results show that the uniformity and stability of diffuse arc plasma are strongly related to the plasma forming gas. Based on these experimental results, an explanation to the arc diffusion is suggested. Moreover, the electron excitation temperature and electron density measured in diffuse helium plasma are much lower than those of constricted arc column, which indicates the diffuse helium plasma probably deviates from the local thermodynamic equilibrium state. Unlike the common non-transferred arc plasma devices, this device can provide a condition for axial-fed feedstock particles. The plasma device is attempted to spheroidize alumina powders by using the central axis to send the powder. Results show that the powder produced is usually a typical hollow sphere.展开更多
Yttria-stabilized-zirconia （YSZ） hollow spheres are widely utilized for their novel physical and chemical properties. However, developing a simple and low-cost method for preparing such hollow spheres still remains ...Yttria-stabilized-zirconia （YSZ） hollow spheres are widely utilized for their novel physical and chemical properties. However, developing a simple and low-cost method for preparing such hollow spheres still remains a great challenge. In this paper, an atmospheric plasma spray （APS） method is introduced, and the formation mechanism of hollow 7YSZ （ZrO2-7wt%Y2O3） spheres is presented. The hollow sphere morphology was observed by scanning electron microscopy （SEM） when agglomerated and sintered 7YSZ powders were used. Additionally, additive composition changes, phase transformations, and the thermal behavior of 7YSZ powders were analyzed by energy dispersive spectroscopy （EDS）, X-ray diffractometry （XRD）, thermogravimetric analysis （TG） and differential scanning calorimeter analysis （DSC）. Furthermore, the phase transformations of agglomerated and sintered 7YSZ powders, 7YSZ hollow spheres that annealed at various temperatures for different times are analyzed.展开更多
文摘Spherical powders with good flowability and high stacking density are mandatory for powder bed additive manufacturing. Nevertheless, the preparation of spherical refractory tungsten and tungsten alloy powders is a formidable task. In this paper, spherical refractory metal powders processed by high-energy stir ball milling and RF inductively coupled plasma were investigated. By utilizing the technical route, pure spherical tungsten powders were prepared successfully, the flowability increased from 10.7 s/50 g to 5.5 s/50 g and apparent density increased from 6.916 g cm-3 to 11.041 g cm-3. Alloying element tantalum can reduce the tendency to micro- crack during tungsten laser melting and rapid solidification process. Spherical W-6Ta （%wt） powders were prepared in this way, homogeneous dispersion of tantalum in a tungsten matrix occurred but a small amount of flake-like shape particles appeared after high-energy stir ball milling. The flake-like shape particles can hardly be spheroidized in subsequent RF inductively coupled plasma process, might result from the unique suspended state of flaky particles under complex electric and magnetic fields as well as plasma-particle heat exchange was different under various turbulence models. As a result, the flake-like shape particles cannot pass through the high-temperature area of thermal plasma torch and cannot be spheroidized properly.
基金funded by ISAM Lab at Missouri University of Science and Technology,Rolla,MO,United States.
文摘The powder characteristics,such as particle size and geometry,play an important role in determining the quality of powder layer and parts fabricated with powder-based additive manufacturing processes.Previous research has found that spherical particles result in better powder flowability and spreadability.An attempt to improve particle sphericity is to process the powder using plasma spheroidization,where the particles heat up,melt,and reshape to spheres.Several research works have been conducted to study the plasma spheroidization process and understand particle-plasma reactions.Although researchers have turned to simulations to overcome the difficulty of experimental study of such reactions,they only characterized the powder particle size without evaluating the particle geometry.In this work,the plasma spheroidization process of copper powder was numerically and experimentally examined to assess the impact of plasma spheroidization on particle size and geometry.For the first time in the literature,a method of simulation was proposed to numerically quantify the particle geometry at each particle residence time.The results of simulation agreed well with those of experiments.
基金financially supported by the 2012 Western Materials Innovation Foundation of China (No. XBCL-1-06)the Science and Technology Coordinating Innovative Engineering Project of Shaanxi Province of China (No. 2014KTCQ01-35)+1 种基金the Natural Science Foundation of Shaanxi Province of China (No. 2014JM6226)the Specialized Research Fund of Education Commission of Shaanxi Province of China (No. 2013JK0905)
文摘To control the morphology and particle size of dense spherical molybdenum powder prepared by radio frequency（RF） plasma from irregular molybdenum powder as a precursor, plasma process parameters were optimized in this paper. The effects of the carrier gas flow rate and molybdenum powder feeding rate on the shape and size of the final products were studied. The molybdenum powder morphology was examined using high-resolution scanning electron microscopy. The powder phases were analyzed by X-ray diffraction. The tap density and apparent density of the molybdenum powder were investigated using a Hall flow meter and a Scott volumeter. The optimal process parameters for the spherical molybdenum powder preparation are 50 g/min powder feeding rate and 0.6 m^3/h carrier gas rate. In addition, pure spherical molybdenum powder can be obtained from irregular powder, and the tap density is enhanced after plasma processing. The average size is reduced from 72 to 62 μm, and the tap density is increased from 2.7 to 6.2 g/cm^3. Therefore, RF plasma is a promising method for the preparation of high-density and high-purity spherical powders.
基金the supports of the Key R&D Program of Advanced Technology of Sichuan Science and Technology Department(No.2020YFG0111)。
文摘Arc plasma torch is an effective tool for spheroidization of metallic powders.However,as most conventional plasma torches were not specifically designed for plasma spheroidization,they may exhibit the disadvantages of the radial injection of powders,large fluctuations in the arc voltage,large gas flow rate,and disequilibrium between multiple plasma jets during the spheroidization process.Therefore,this paper presents a triple-cathode cascade plasma torch(TCCPT)for plasma spheroidization.Its structural design,including three cathodes,a common anode,and three sets of inter-electrodes,are detailed to ensure that powders can be inserted into the plasma jet by axial injection,the arc voltage fluctuations are easily maintained at a low level,and the plasma torches can work at a relatively small gas flow rate.Experimental results showed that the proposed TCCPT exhibits the following characteristics:(1)a relatively small arc voltage fluctuation within 5.3%;(2)a relatively high arc voltage of 75 V and low gas flow rate range of10-30 SLM;(3)easy to be maintained at the equilibrium state with the equilibrium index of the three plasma jets within 3.5 V.Furthermore,plasma spheroidization experiments of SUS304 stainless steel powers were carried out using the proposed TCCPT.Results verified that the proposed TCCPT is applicable and effective for the spheroidization of metallic powders with wide size distribution.
基金Project (20101101120030) supported by International Graduate Exchange Program of Beijing Institute of Technologysupported by the Research Fund for the doctoral Program of Higher Education of China
文摘In order to prepare high quality Mo（Si,Al）2 feedstock characterized with C40 phase, higher Al doping amount andexcellent flowability, Mo（Si1-x,Alx）2 with different Al contents （x=0, 0.1, 0.2, 0.3, 0.4, 0.5） were synthesized by self-propagatinghigh-temperature synthesis first and Mo（Si0.6,Al0.4）2 was confirmed as the suitable material through X-ray diffraction analysis. Aseries of tests with different parameters of induction plasma spheroidization were applied to improving the flowability of feedstock.Mo（Si,Al）2 feedstock with excellent flowability （26.2 s/50 g） was prepared through adding hydrogen into sheath gas and decreasingthe powder feeding rate. The composition segregation occurred in the spheroidized powder after Al consumption and oxidation. Theinhomogeneous structure of the same particle was caused by the asymmetric heating and cooling when particle passed through theplasma jet.
基金Project supported by the National Natural Science Foundation of China(Grant Nos.11475174 and11035005)the Fundamental Research Funds for the Central Universities,China(Grant No.WK2090130021)
文摘An arc channel at atmospheric pressure tends to shrink generally. In this paper, a non-transferred DC arc plasma device with multiple cathode is introduced to produce a large area arc plasma at atmospheric pressure. This device is comprised of a 42-mm diameter tubular chamber, multiple cathode which is radially inserted into the chamber, and a tungsten anode with a nozzle in its center. In argon/helium atmosphere, a large area and circumferential homogenous diffuse arc plasma, which fills the entire cross section surrounded by the cathode tips, is observed. Results show that the uniformity and stability of diffuse arc plasma are strongly related to the plasma forming gas. Based on these experimental results, an explanation to the arc diffusion is suggested. Moreover, the electron excitation temperature and electron density measured in diffuse helium plasma are much lower than those of constricted arc column, which indicates the diffuse helium plasma probably deviates from the local thermodynamic equilibrium state. Unlike the common non-transferred arc plasma devices, this device can provide a condition for axial-fed feedstock particles. The plasma device is attempted to spheroidize alumina powders by using the central axis to send the powder. Results show that the powder produced is usually a typical hollow sphere.
基金supported by TBCs research team at Guangzhou Research Institute of Non-ferrous Metalsthe National "973" Basic Research Project of China (2012CB625100) for providing financial support
文摘Yttria-stabilized-zirconia （YSZ） hollow spheres are widely utilized for their novel physical and chemical properties. However, developing a simple and low-cost method for preparing such hollow spheres still remains a great challenge. In this paper, an atmospheric plasma spray （APS） method is introduced, and the formation mechanism of hollow 7YSZ （ZrO2-7wt%Y2O3） spheres is presented. The hollow sphere morphology was observed by scanning electron microscopy （SEM） when agglomerated and sintered 7YSZ powders were used. Additionally, additive composition changes, phase transformations, and the thermal behavior of 7YSZ powders were analyzed by energy dispersive spectroscopy （EDS）, X-ray diffractometry （XRD）, thermogravimetric analysis （TG） and differential scanning calorimeter analysis （DSC）. Furthermore, the phase transformations of agglomerated and sintered 7YSZ powders, 7YSZ hollow spheres that annealed at various temperatures for different times are analyzed.
