About this Abstract |
| Meeting |
2026 TMS Annual Meeting & Exhibition
|
| Symposium
|
Additive Manufacturing and Innovative Feedstock Processing for Multifunctional Materials
|
| Presentation Title |
Ultrasonic Atomization of Lightweight Alloys for Additive Manufacturing: Processing of Al- and Mg-Based Alloys |
| Author(s) |
Tomasz Choma, Bartosz Kalicki, Bartosz Moronczyk, Jakub Ciftci, Lukasz Zrodowski |
| On-Site Speaker (Planned) |
Tomasz Choma |
| Abstract Scope |
Lightweight alloy powders, particularly those based on aluminum and magnesium, are of growing interest for Additive Manufacturing (AM) due to their high strength-to-weight ratios. However, the availability of spherical, high-quality powders in small batches for research and alloy development remains limited. This work presents an ultrasonic atomization platform that combines induction melting with high-frequency ultrasonic excitation to enable flexible processing of both commercial and custom Al- and Mg-based alloys.
Atomization trials were conducted using sonotrodes operating at 40 and 60 kHz to assess the influence of frequency on particle size distribution, morphology, and compositional homogeneity. Powders were characterized using Dynamic Image Analysis (DIA), scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy (EDS). The results reveal clear frequency-dependent trends in PSD, and confirm uniform sphericity and chemical distribution across particles. The process demonstrates excellent compatibility with volatile alloying elements and enables rapid prototyping of novel alloy compositions for AM. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Additive Manufacturing, Powder Materials, Magnesium |