Additive Manufacturing with Non-Ferrous Powders Exhibiting a Wide Particle Size Distribution

PROJECT COST:

258 467 $

PRIMA CONTRIBUTION:

59 590 $

PROJECT DETAILS:

Metal powders are widely used in additive manufacturing (AM) processes to produce components with homogeneous microstructures and acceptable levels of porosity. When powder quality remains consistent, optimized processing parameters can be established to ensure robust and reliable manufacturing. However, a major technical challenge is the ability to process metallic powders exhibiting variations in their characteristics. In such cases, AM processing parameters must be adapted to guarantee the minimum in-service properties required for the manufactured components. In particular, the particle size distribution of metal powders significantly influences the resulting microstructure, the formation of defects, and their maximum size, both at the surface and within the material. These defects directly affect the mechanical properties and in-service performance of AM parts.

Understanding the combined effects of metal powder characteristics and processing parameters on the certification of component performance has become essential for rapid manufacturing, especially in the context of Industry 4.0. This project aims to address these challenges by improving the understanding of powder–process interactions and developing solutions to enhance the versatility of conventional 3D printing systems. As a result, AP&C will strengthen its state-of-the-art expertise in powder characterization and gain a deeper understanding of how subtle variations in powders and powder blends influence the final properties of manufactured components, enabling more effective guidance for its customers.