| Abstract Scope |
In powder bed additive manufacturing (AM), including electron beam (EB-AM) and laser powder bed fusion (L-PBF), achieving high-density powder beds requires powders not only with superior sphericity and circularity but also minimal electrostatic charge accumulation. Powders exhibiting thin surface oxide films and low or zero capacitance significantly reduce electrostatic interactions, promoting uniform layering. Additionally, eliminating gas-induced porosity introduced during atomization is essential to enhance powder integrity and final component quality. Plasma rotating electrode process (PREP) powders effectively address these criteria, producing defect-free powders compared to conventional gas-atomized powders, which inherently contain gas porosity. Utilizing PREP powders in conjunction with machine learning-driven optimization of AM processes results in components with markedly superior mechanical properties, surpassing parts manufactured with gas-atomized powders and even exceeding those produced by conventional forging. This study underscores the importance of powder composition, characterization, and optimized processing conditions across various AM technologies. |