FABRICATION OF METAL POWDER FOR ADDITIVE MANUFACTURING USING ULTRASONIC ATOMIZER

Abstract

Complex geometries and patterns that are challenging or impossible to produce using conventional manufacturing methods can be produced using metal powders. This is due to the fact that layer-by-layer part construction is possible with additive manufacturing technologies, which enhances design flexibility and personalization. This study investigated the feasibility of using ultrasonic atomization to fabricate Stainless Steel 316L powder for additive manufacturing. The powder was produced using an ultrasonic atomizer and characterized for its physical and flowability properties. The results were compared with commercially available Stainless Steel 316L powder. This study's objective is to assess and contrast these powders' physical properties and flowability. For the Stainless Steel 316L, the particle size distribution analysis showed that the ultrasonic atomized powder had a narrower size distribution and more spherical particles than the commercially available powder. The scanning electron microscopy analysis shows that the ultrasonic atomized powder had a smooth surface and fewer defects than the commercially available powder. The rheometer tests showed that the ultrasonic atomized powder had better flowability and packing characteristics than the commercially available powder. The Carr's index, porosity, tap density, and Hausner ratio measurements also showed that the ultrasonic atomized powder had better flowability and packing characteristics. By 3Dprinting a typical tensile sample and performing tensile and hardness tests on it, the study evaluated the performance of SS 316L powder on SLM. As a result of the material's mechanical qualities falling within the permissible range, the results demonstrated that it is suitable for usage in projects or goods. This highlights the significance of reliable testing protocols and quality control systems. By modifying processing parameters for various powders, the study's conclusions can assist and enhance the effectiveness of additive manufacturing techniques. These findings suggest that ultrasonic atomization is a promising technique for producing Stainless Steel 316L powder for additive manufacturing with improved physical and flowability properties. And it also provides valuable insights for optimizing the production process of Stainless Steel 316L metal powder for additive manufacturing applications