This study investigates the potential of Twin Wire-Arc Spray (TWAS) as a method for producing316 stainless steel (SS) powders optimized for additive manufacturing (AM) applications. Particle sizedistribution (PSD) analysis confirmed a D50 of 57.55 𝜇m, well within the range required for powder bedfusion AM. Over 95% of the powders exhibited high sphericity, as shown through scanning electronmicroscopy, enhancing their flowability—an essential trait for AM. Vickers hardness measurementsrevealed that the 316 SS powders produced by TWAS achieved a significantly higher hardness (384 HV)compared to conventional gas-atomized powders (273 HV), highlighting the high cooling rate of thisprocess. Microstructural analysis of solidification behavior identified diverse structural formations, fromdendritic to cellular to planar, corresponding to variations in cooling rates. Additionally, the presence ofchromium in the powders contributed to a protective oxide layer, reducing porosity and enhancing corrosionresistance, both vital for AM applications. These findings underscore the suitability of TWAS for producing316 SS powders with the structural and mechanical properties desired for powder bed fusion additivemanufacturing.
Mohammadamin Kalateh (Tue,) studied this question.
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