Characterization, preparation, and reuse of metallic powders for laser powder bed fusion: a review

Laser powder bed fusion(L-PBF) has attracted significant attention in both the industry and academic fields since its inception, providing unprecedented advantages to fabricate complex-shaped metallic components. The printing quality and performance of L-PBF alloys are infuenced by numerous variables consisting of feedstock powders, manufacturing process,and post-treatment. As the starting materials, metallic powders play a critical role in infuencing the fabrication cost, printing consistency, and properties. Given their deterministic roles, the present review aims to retrospect the recent progress on metallic powders for L-PBF including characterization, preparation, and reuse. The powder characterization mainly serves for printing consistency while powder preparation and reuse are introduced to reduce the fabrication costs.Various powder characterization and preparation methods are presented in the beginning by analyzing the measurement principles, advantages, and limitations. Subsequently, the effect of powder reuse on the powder characteristics and mechanical performance of L-PBF parts is analyzed, focusing on steels, nickel-based superalloys, titanium and titanium alloys, and aluminum alloys. The evolution trends of powders and L-PBF parts vary depending on specific alloy systems, which makes the proposal of a unified reuse protocol infeasible. Finally,perspectives are presented to cater to the increased applications of L-PBF technologies for future investigations. The present state-of-the-art work can pave the way for the broad industrial applications of L-PBF by enhancing printing consistency and reducing the total costs from the perspective of powders.

Study of the reaction mechanism for preparing powdered activated coke with SO_(2)adsorption capability via one-step rapid activation method under flue gas atmosphere

In this study,the impact of different reaction times on the preparation of powdered activated carbon(PAC)using a one-step rapid activation method under flue gas atmosphere is investigated,and the underlying reaction mechanism is summarized.Results indicate that the reaction process of this method can be divided into three stages:stage I is the rapid release of volatiles and the rapid consumption of O_(2),primarily occurring within a reaction time range of 0-0.5 s;stage II is mainly the continuous release and diffusion of volatiles,which is the carbonization and activation coupling reaction stage,and the carbonization process is the main in this stage.This stage mainly occurs at the reaction time range of 0.5 -2.0 s when SL-coal is used as material,and that is 0.5-3.0 s when JJ-coal is used as material;stage III is mainly the activation stage,during which activated components diffuse to both the surface and interior of particles.This stage mainly involves the reaction stage of CO_(2)and H2O(g)activation,and it mainly occurs at the reaction time range of 2.0-4.0 s when SL-coal is used as material,and that is 3.0-4.0 s when JJ-coal is used as material.Besides,the main function of the first two stages is to provide more diffusion channels and contact surfaces/activation sites for the diffusion and activation of the activated components in the third stage.Mastering the reaction mechanism would serve as a crucial reference and foundation for designing the structure,size of the reactor,and optimal positioning of the activator nozzle in PAC preparation.

Preparation and Characterization of CeO_2 Superfine Powder

The CeO_2 superfine powder was prepared by the co-precipitation method, using the industrial grade Ce_2(CO_3)_3 and NH_4HCO_3 as starting material and precipitating reagent, respectively. The precipitated precursons and the calcinated products were characterized by the thermogravimetric analysis/thermoanalysis (TGA/DTA), X-ray diffraction analysis (XRD) and transmission electron microscopy (TEM). The results show that using NH_4HCO_3 as a precipitating reagent, the precipitate decomposed full as it was heated to 360 ℃. The CeO_2 superfine powder formed by calcinating the precipitate belongs to a cubic CaF_2-type structure and has the first mean particle diameter 140 nm and second mean particle diameter 630 nm. The CeO_2 powder particles aggregate and grow with raising the calcination temperature.

Preparation of ultrafine silver powders with controllable size and morphology

The ultrafine silver powders were prepared by liquid reduction method using Arabic gum as dispersant.The effects of different dispersants,pH values,and temperature on the morphology and particle size of silver powders were investigated.It is found that Arabic gum can better adsorb on silver particles via chemical adsorption,and it shows the best dispersive effect among all the selected dispersants.The particle size of silver powders can be finely tuned from 0.34 to 4.09μm by adjusting pH values,while the morphology of silver powders can be tuned by changing the temperature.The silver powders with high tap density higher than 4.0 g/cm3 were successfully prepared in a wide temperature range of 21.8-70°C.Especially,the tap density is higher than 5.0 g/cm3 when the temperature is optimized to be 50°C.The facile process and high silver concentration of this method make it a promising way to prepare high quality silver powders for electronic paste.

Preparation and Properties of Nano-TiO_2 Powders

This paper reports the preparation of nano-TiO2 (about 10 nm) powder by the method of precipitation. In detail, some breparation conditions were investigated in order to find out how to control the grain size and reduce the agglomeration of powders. Also, the reflex spectra of nano-scale powders with different grain size were studied. It tvas found that the wave length and width of reflex spectra are connected with the grain size of nano-TiO2 powders

Preparation of Ultrafine Cobalt Powder by Chemical Reduction in Aqueous Solution

Nanocrystalline cobalt powders have been prepared from aqueous solution by reducing their corresponding metal salts under suitable conditions. The experimental conditions have been studied in detail. X-ray powder diffraction patterns show that the cobalt powder is hexagonal crystallite. The average particle size of the ultrafine cobalt powder is 55 nm.

Hydrothermal preparation and crystal habit of X-zeolite powder

The preparation of X-zeolite powder was investigated in hydrothermal system, the crystal growth process of X-zeolite in hydrothermal condition was characterized by means of X-ray diffraction, scanning electron microscope and infrared ray. The results show that X-zeolite powder with uniform granularity and intact crystal shape can be obtained in hydrothermal system of acid-treated stellerite KG-*5CD*2KG-*9NaOHKG-*5CD*2KG-*9NaAl（OH）4KG-*5CD*2KG-*9H2O; the crystallite size is in the range of 2CD*23μm. The best reaction time of hydrothermal preparation is 6h. The formation phases of X-zeolite crystal are as follows: dissolution of feedstocks → formation of [SiO4] 4- and [AlO4] 5- tetrahedron, many-membered ring, β cage → formation of crystal nucleus and nano-particle → aggregation growth of nano-particle → coalescence growth of crystallite. The crystal habits of X-zeolite are intimately related with crystallization orientation of β cage in crystal and with its coupling stability on every crystal face family.

PREPARATION AND CHARACTERIZATION OF SILICA GEL POWDERS

Silica gel powders,with particle diameter in the range 10 to 20 nm,were prepared from water glass using ethyl acetate as a latent acid reagent. The products were characterized by TGDTA, TEM, FTIR, BET and some other experiment methods. The process of silica solgel formation and the thermal behavior as well as phase change of the silica powders during heattreating process were studied, and the effect of heattreating temperature on the specific surface area and apparent density of the silica powders was investigated.

PREPARATION OF NANOSTRUCTURED TUNGSTEN POWDERS

The preparation of nanostructured tungsten powders has been studied by using the characteristics of high-er temperature, higher chemical reactivity and quenching technology of hydrogen plasma,in which WO3 solid particles served as raw materials. The reduction mechanism of WO3 at high temperature has been also discussed. The composition . particle size distribution and morphology of nanostructured tungsten powders have been measured by X?ray diffraction small angle X-ray scatter and TEM. Tungsten powders of mean particle size of 40 nanometer,and specific surface area of 3 X10m2/kg have been prepared. The shape of nanostruc-tutted tungsten powders is sphere.

CARBOTHERMAL PREPARATION OF Si_2N_2O FROM NATURAL QUARTZ POWDER

Si2N2O powder was synthesized by car-bothermal reduction and nitridation natural quartz powder. At the same time, the effects of the process parameters such as SiO2/C ratio, temperature and time on the compositions of products were analysed. It is found that the compositions of products depend closely on the parameters mentioned above, and that the product containing higher Si2N2O phase could be obtained by choosing suitable process parameters.

Preparation of Ultra-fine Salbutamol Sulfate Particles by Reactive Precipitation and Characterization of Dry Powder Inhalant

The preparation of ultra-fine particles of salbutamol sulphate （SS） was accomplished with a reactive precipitation pathway, in which salbutamol and sulphuric acid were Used as reactants with the solvents of ethanol.The effects of sulphuric acid concentration, reaction temperature, stirring rate, and reaction time onthesize of the particle were investigated. A binary mixture composed of lactose and SS was prepared to evaluate SS. The results showed that ultra-fine SS particles with controlled diameters ranging between 3 μm and 0.8 μm and with a narrow distribution could be achieved. The morphology consisting of clubbed particles wassuccess.fully obtained. The purity of the particles reached above 98% with-UV detection. The dose- of dry powder inhalation was obtained by blending the particles with recrystallized lactose, which acted as a carrier. The deposition quantity of the drug in breathing tract was estimated using a twin imPinger apparatus. Compared with the Shapuer powder （purchased in the market）, the results showed that SS_particles had more quantifies.subsided in simulative lung.. _

Preparation and characterization of neodymium hydroxide powder via the hydration method

The preparation of Nd(OH)3 powder by the direct hydration method using Nd2O3 as a raw material was studied,and the effects of stirring mode,H2O and Nd2O3 molar ratio,stirring rate,and reaction time on temperature change and conversion rate in a hydration system were analyzed.The reasonable process conditions for the direct hydration of Nd(OH)3 by Nd2O3 were then determined.Process,morphology,and structure were considered in the preparation of neodymium hydroxide powder,and its composition was investigated by X-ray powder diffraction,scanning electron microscopy,laser particle size analysis,thermogravimetric differential thermal analysis,and chemical analysis.It has been proved that the process is simple and feasible,in line with the concept of modern green chemistry,and the products also meet the market requirements.

Preparation of Ultrafine Si Powders from SiH_4 by Laser-induced Gas Phase Reaction

High quality ultrafine Si powders have been synthesized from SiH4 by laser induced gas phase reaction. The powders prduced under different synthesis conditions have mean particle size of 10-120nm in diam. with narrow particle size distribution, and free of hard agglomerates.The powders are polycrystalline with the ratio of mean grain to particle diameter being between 0.3-0.7. The size of the powder increases with increasing laser power and reaction pressure,but decreases with increasing silane gas flow rate and the addition of Ar diluent. Grain sizes drop distinctly with the rise of the addition of Ar gas and laser power, but change little with the gas flow rate and reaction temperature. The formation of Si particles under different synthesis conditions is discussed

Preparation of GaN Powder of Nanometer Scale by MOCVD Using DEGA as Precursor

GaN powder of nanometer scale was prepared by metal organic chemical vapor deposition using diethylgallium azide as precursor. The resulting powder was characterized by XRD and TEM. It has been found that the particle size of the powder obtained is affected by the deposition temperature, and the fine crystals formed in temperature range 500 similar to 650 degrees C were hexagonal.

Preparation of Strontium Bismuth Tantalum (SBT) Fine Powder by Sol-Gel Process Using Bismuth Subnitrate as Bismuth Source

Strontium bismuth tantalum (SBT) fine power was prepared by Sol-Gel method. Pentaethoxy tantalum, strontium acetate and bismuth subnitrate were used as raw materials, and were dissolved in proper order in ethylene glycol to form transparent sol. The mixed precursor was dried at 80℃ and annealed at 800℃ for 1 h. Crystallized nanometer sized SBT fine powder was obtained and characterized by XRD.

In-situ Preparation of Al/TiAl_3(P) Composite by Direct Reaction between Molten Al and TiO_2 Powder

TiAl3 particle reinforced pure Al composite has been made by direct reaction among molten Al, TiO2 and a flux. The composite exhibits high Synthetically properties. The strength and hardness are higher than those of pure Al matrix by 71.5% and 134% respectively However, the elongation is 20.36%, slightly lower than that of the Al matrix.

Preparation of Ni/C core-shell composite powders by electroless plating method

Ni/C core-shell composite powders were prepared by electroless nickel-plating. The effects of concentration of NiSO4,bathing temperature,ratio of hydrazine hydrate to NiSO4,pH of the solution,amounts of complexing reagent and surfactant,bath load of activated carbon and reaction time,and so on,on the preparation of Ni/C core-shell composite powders were studied. The results show that the principal factors for Ni/C composite powders preparation are bathing temperature,ratio of hydrazine hydrate to NiSO4 and pH of the solution. The optimum conditions are plating at 90 ℃ with pH10.7 and molar ratio of N2H4·H2O to Ni2+of 3.0. The plated nickel powders are observed to be sphere-like in morphology with size about 100 nm. The maximum dielectric loss of Ni/C core-shell composite powders is about 0.35,and its magnetic loss was low with value about 0 in 2-16 GHz.

Ultramicro molybdenum nitride powder prepared using high-energy mechanochemical method

Using the specially designed mechanochemical ball-mill equipment, ultramicro molybdenum nitride powders were prepared from pure molybdenum powders in ammonia atmosphere at room temperature by high-energy ball milling. The structure and the particle size of the powders were investigated by X-ray diffraction （XRD）, scanning electron microscopy （SEM）, and transmission electron microscopy （TEM）. The results show that the mass ratio of grinding media to powder was 8：1, after milling for 30 h the Mo2N of fcc structure was obtained, and the average particle size of the powders was around 100 nm. It is found that the chemisorption of ammonia onto the fresh molybdenum surfaces created by milling was the predominant process during solid-gas reaction, and the energy input due to introduction of highly dense grain boundaries and lattice defects offered the activation energy for the transition from Mo-N chemisorption to molybdenum nitride. In addition, the change of Mo electronic undersaturation induced by the grain refining accelerated the bonding between Mo and N. The mechanism model of whole nitriding reaction was given, During the high-energy ball milling processing, the rotational speed of milling played a critical role in determining the overall reaction speed.

Preparation of high purity vanadium nitride by magnesiothermic reduction of V2O3 followed by nitriding in N2 atmosphere

High purity vanadium nitride(VN)powders were prepared via a two-step process using vanadium trioxide(V2 O3)as the raw material.The V2 O3 was firstly reduced at 873 K in Ar atmosphere via magnesiothermic reduction reaction to get the mixture of V and MgO,and then the products were further nitrided at 1473 K in N2 atmosphere.Finally,the as-prepared samples were acid-leached to obtain pure VN powders.X-ray diffractometry and field-emission scanning electron microscopy were used to analyze the phase transition and morphological evolution of the samples.The results reveal that the overall morphology of the obtained VN powder retains the morphology of the initial V2 O3 powders.After removing MgO by acidic leaching,the porous VN particles can be obtained,with the oxygen content of 0.178 wt.%.Compared with the traditional methods,high purity VN powders with a small amount of oxygen and no carbon can be obtained.

Preparation of Compound Ultrafine CeO2 by Wet-Solid-Phase Mechanochemical Modification

To satisfy practical requirements from industrial applications, an alternate route for synthesis compound ultrafine CeO2 powders by wet-solid-phase mechanochemical modification using industrial grade hydrated cerium carbonate as raw material was proposed.The effect of modifier reaction percentage, reaction time, calcining temperature and modifier amount on particle size, density, suspensibility, and hardness of compound CeO2 powder was investigated.The phase evolutions of preparation process were characterized by XRD.SEM micrograph of the final product shows that compound CeO2 powders obtained are well-dispersed, spherically-shaped, uniformly-sized and submicron-sized particles.The method is readily available in raw material, low in cost, simple in process, and has great potential for industrialization.The compound CeO2 powders of different physical properties can be synthesized by controlling the above-mentioned influence factors in preparation process.