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...
Saved in:
| Main Authors: | , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
Elsevier
2025-07-01
|
| Series: | Additive Manufacturing Letters |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S2772369025000465 |
| Tags: |
Add Tag
No Tags, Be the first to tag this record!
|
| _version_ | 1849232656500260864 |
|---|---|
| author | Gökhan Ertugrul Aliakbar Emdadi Sebastian Härtel |
| author_facet | Gökhan Ertugrul Aliakbar Emdadi Sebastian Härtel |
| author_sort | Gökhan Ertugrul |
| collection | DOAJ |
| description | 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. |
| format | Article |
| id | doaj-art-e0148ca4e5474fe5aa5e07182324aa5f |
| institution | Kabale University |
| issn | 2772-3690 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Additive Manufacturing Letters |
| spelling | doaj-art-e0148ca4e5474fe5aa5e07182324aa5f2025-08-21T04:17:57ZengElsevierAdditive Manufacturing Letters2772-36902025-07-011410031310.1016/j.addlet.2025.100313Powder production and additive manufacturing of iron aluminide alloys using plasma ultrasonic atomization and laser-directed energy depositionGökhan Ertugrul0Aliakbar Emdadi1Sebastian Härtel2Chair of Hybrid Manufacturing, Brandenburg University of Technology, Cottbus, Germany; Corresponding authors.Chair of Physical Metallurgy and Materials Technology, Brandenburg University of Technology, Cottbus, GermanyChair of Hybrid Manufacturing, Brandenburg University of Technology, Cottbus, GermanyWith 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.http://www.sciencedirect.com/science/article/pii/S2772369025000465Iron Aluminides (Fe-Al)Additive ManufacturingLaser-Directed Energy Deposition (L-DED)Process ChainPlasma Ultrasonic AtomizationPowder |
| spellingShingle | Gökhan Ertugrul Aliakbar Emdadi Sebastian Härtel Powder production and additive manufacturing of iron aluminide alloys using plasma ultrasonic atomization and laser-directed energy deposition Additive Manufacturing Letters Iron Aluminides (Fe-Al) Additive Manufacturing Laser-Directed Energy Deposition (L-DED) Process Chain Plasma Ultrasonic Atomization Powder |
| title | Powder production and additive manufacturing of iron aluminide alloys using plasma ultrasonic atomization and laser-directed energy deposition |
| title_full | Powder production and additive manufacturing of iron aluminide alloys using plasma ultrasonic atomization and laser-directed energy deposition |
| title_fullStr | Powder production and additive manufacturing of iron aluminide alloys using plasma ultrasonic atomization and laser-directed energy deposition |
| title_full_unstemmed | Powder production and additive manufacturing of iron aluminide alloys using plasma ultrasonic atomization and laser-directed energy deposition |
| title_short | Powder production and additive manufacturing of iron aluminide alloys using plasma ultrasonic atomization and laser-directed energy deposition |
| title_sort | powder production and additive manufacturing of iron aluminide alloys using plasma ultrasonic atomization and laser directed energy deposition |
| topic | Iron Aluminides (Fe-Al) Additive Manufacturing Laser-Directed Energy Deposition (L-DED) Process Chain Plasma Ultrasonic Atomization Powder |
| url | http://www.sciencedirect.com/science/article/pii/S2772369025000465 |
| work_keys_str_mv | AT gokhanertugrul powderproductionandadditivemanufacturingofironaluminidealloysusingplasmaultrasonicatomizationandlaserdirectedenergydeposition AT aliakbaremdadi powderproductionandadditivemanufacturingofironaluminidealloysusingplasmaultrasonicatomizationandlaserdirectedenergydeposition AT sebastianhartel powderproductionandadditivemanufacturingofironaluminidealloysusingplasmaultrasonicatomizationandlaserdirectedenergydeposition |