Innovative Al-Based Powders Through Ultrasonic Vibration And Gas Atomizing

The need for spherical powders with enhanced flowability and tailored compositions have brought on new atomization techniques particularly suited for the lab-scale and highly competitive R&D activities. Among metal atomization techniques suitable for lab-scale development, those assisted by ultrasonic vibration are experiencing a notable diffusion at the R&D level. Gas-atomization is, however, the primary technique for producing spherical powders when larger batches are needed for production or R&D purposes. The present study analyses the characteristics of an innovative Al-Cu-Ti-Fe-Cr alloy obtained by the two powder production techniques. At first, the two atomization processes are compared in terms of yield in specific PSD ranges, a peculiarity of the AM technologies. Then, the main body of the study presents the characterization and comparison of the powders in terms of morphology and microstructure.