Powder production and additive manufacturing of iron aluminide alloys using plasma ultrasonic atomization and laser-directed energy deposition
With a combination of desirable properties such as low density, high specific yield strength, low material cost, and excellent oxidation and corrosion resistance, iron aluminide (Fe-Al) has shown considerable potential to be an alternative to high-alloy chromium steels, and in some cases even nickel...
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| Main Authors: | , , |
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| Format: | Article |
| Language: | English |
| Published: |
Elsevier
2025-07-01
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| Series: | Additive Manufacturing Letters |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S2772369025000465 |
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| Summary: | With a combination of desirable properties such as low density, high specific yield strength, low material cost, and excellent oxidation and corrosion resistance, iron aluminide (Fe-Al) has shown considerable potential to be an alternative to high-alloy chromium steels, and in some cases even nickel-based superalloys, in high-temperature applications. Due to these features, it is especially suitable for the aerospace and automotive industries. Recent advancements indicate an increasing interest in Fe-Al within the additive manufacturing industry, particularly in directed energy deposition (DED) processes. Despite this progress, processing of Fe-Al materials using the laser directed energy deposition (L-DED) has not been sufficiently investigated. In this study, Fe-Al powder material was produced from a commercial Al rod encased in a commercial low alloy-steel tube by a plasma-based ultrasonic atomization eliminating the need to cast an alloy ingot in advance. Subsequently, the produced powder was used in a l-DED process to fabricate an additively manufactured sample. The sample was investigated in terms of mechanical property, microstructure, chemical composition, and phase structure by scanning electron microscope (SEM) / energy dispersive X-ray spectroscopy (EDX), X-ray diffraction (XRD), electron backscatter diffraction (EBSD) and microhardness analyses. |
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| ISSN: | 2772-3690 |