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Meeting MS&T25: Materials Science & Technology
Symposium Additive Manufacturing: Development of Powders
Organizer(s) Tim Horn, North Carolina State University
Ian McQue, Northwestern University
Iver Anderson, Ames National Laboratory
Michael Kirka, Oak Ridge National Laboratory
Scope Metal powder production has a long and rich history, playing a pivotal role in various industrial applications such as critical aerospace components, tooling, coatings, and automotive. Techniques such as gas atomization, fluid atomization, plasma atomization, plasma spherodization, centrifugal atomization, and high-energy kinetic methods have been refined over decades, resulting in substantial scientific literature and technical expertise. Despite this extensive background, interest in novel alloys for additive manufacturing (AM) has led to the widespread proliferation of pilot-scale and lab-scale powder production systems which have been deployed in universities, national laboratories, and industry.

This has led to critical gaps necessitating this symposium, including a disconnect between traditional powder production experts and AM users, which has led to inefficiencies and repeated mistakes. There is insufficient dissemination of historical knowledge and recent advancements in powder production to new users in the AM field. Emerging safety concerns and handling protocols for powders used in AM, which differ from traditional applications, also need to be addressed. Moreover, there is a need for improved process monitoring, control, and optimization to meet the needs of the AM.

The symposium will focus on bridging the gap between traditional powder production and the scientific needs of the AM community. It will encompass presentations by experts on the evolution of metal powder production techniques and their applications in various fields, providing historical perspectives as well as state-of-the-art research and offering insights into recent advancements and innovative techniques in powder production specifically tailored for AM. Detailed discussions from a scientific perspective will cover safety protocols, hazard mitigation, and best practices for handling metal powders in an AM environment. The symposium will explore metallurgical principles and the modeling and development of new alloys suited for AM processes. Techniques for real-time monitoring, feedback control, and optimization of powder production processes to ensure high quality and consistency such as nozzle design and droplet breakup modeling, will be examined. Finally, the symposium will address powder post-processing techniques, including powder recovery, coating, milling, recycling, and quality assurance.

It is the intent of the organizers that this symposium will challenge the audience's perceptions by highlighting the critical importance of integrating historical knowledge with modern advancements. It will push participants to reconsider traditional methods in light of the unique demands of AM, promoting a more holistic and innovative approach to powder production. By bringing together diverse perspectives, The symposium will facilitate knowledge exchange between traditional experts and new users, fostering collaboration and innovation. Attendees will gain a deeper understanding of the historical context, current challenges, and future directions in the field. The session will enhance participants' understanding of the historical evolution and current state of metal powder production. It will provide insight into the specific challenges and opportunities associated with the various techniques for powder production and provide a platform for discussing and debating key topics, sharing knowledge, and driving innovation, ultimately supporting the growth and success of additive manufacturing.

The topics covered in this symposium are directly relevant to the future of the workforce and graduate student education. As AM continues to grow, there is a need for a new generation of engineers and scientists who are well-versed in both traditional and novel powder production techniques. This symposium will provide invaluable insights and learning opportunities for students and early-career professionals, helping to prepare them for the challenges and opportunities in the field. Additionally, fostering collaboration between academia and industry will enhance educational programs, ensuring that they remain aligned with the latest technological advancements and industry needs.

Abstracts Due 05/01/2025
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