Ultra-low cost Ti powder for selective laser melting additive manufacturing and superior mechanical properties associated

Yuhang Hou; Bin Liu; Yong Liu; Yinghao Zhou; Tingting Song; Qi Zhou; Gang Sha; Ming Yan

doi:10.29026/oea.2019.180028

Opto-Electronic Advances, Volume. 2, Issue 5, 180028-1(2019)

Ultra-low cost Ti powder for selective laser melting additive manufacturing and superior mechanical properties associated

Yuhang Hou¹, Bin Liu², Yong Liu², Yinghao Zhou¹, Tingting Song³, Qi Zhou⁴, Gang Sha⁴, and Ming Yan^1、*

Author Affiliations

¹Department of Materials Science and Engineering, and Shenzhen Key Laboratory for Additive Manufacturing of High-performance Materials, Southern University of Science and Technology, Shenzhen 518055, China

²The State Key Laboratory of Powder Metallurgy, Central South University, Changsha 410083, China

³School of Aerospace, Mechanical and Manufacturing Engineering, Centre for Additive Manufacturing, RMIT University, Melbourne, VIC 3001, Australia

⁴School of Materials Science and Engineering, Nanjing University of Science and Technology, Nanjing 210094, China

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Figures & Tables(9)

Fig. 1. SEM images of the various HDH-Ti powders modified by the ball milling processing using different parameters.

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Fig. 2. (a) SEM-SE image of unmodified HDH-Ti powder. (b) SEM-SE image of the modified HDH-Ti powder which shows near spherical morphology. (c) The powder spread record for the unmodified HDH-Ti powder (fails to spread onto substrate). (d) The powder spread record for the modified HDH-Ti powder (which is printable). (e) Particle size distribution before and after powder modification. (f) XRD results for the powders before and after powder modification.

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Fig. 3. Powder morphology variation using different amount of PCA, (a) 0 wt.%, (b) 1 wt.% and (c) 0.2 wt.%, and (d) schematic graph to show the effect of PCA on the powder modification. The original TiO₂ film on top of powder surface may get resolved into Ti matrix during SLM process.

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Fig. 4. (a) XRD patterns for the as-printed Ti using modified powder and spherical powder. (b) SEM-SE image of the as-printed Ti using the modified powder; figure inset is a TEM-BF image. (c) EBSD result for the modified CP-Ti powder. (d) EBSD result for the as-purchased CP-Ti powder. (e) Tensile test of the as-printed Ti using the modified powder, with a comparative curve based on the commercial spherical Ti powder. (f) Fractography of the as-printed Ti using the modified powder, where inclusion can be occasionally found as the one marked out. (g) 3D APT results showing the oxygen distribution across the tip sample. (h) and (i) The corresponding concentration profiles of oxygen and Fe, and (j) schematic graph of part of a Ti-Fe binary phase diagram.

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Fig. 5. (a) Comparison of the prices of a variety of Ti materials highlighting the ultralow cost Ti powder developed in this study. (b) Comparison of the mechanical properties among some typical Ti materials. (c) The Brinell hardness of the as-printed CP-Ti using commercial, spherical powder and modified powder; the latter shows better hardness due to enlarged concentration of N, O and Fe.

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Table 1. Particle size distribution, D50 and flowability score modified with different parameters. Parameter set No. D (underlined) shows the best combination of flowability and D50 values.

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Table 1. Particle size distribution, D50 and flowability score modified with different parameters. Parameter set No. D (underlined) shows the best combination of flowability and D50 values.

No.	Rotation speed (rpm)	Ball to materialal ratio	Process time (h)	D50 (μm)	Flowability score
Unmodified	-	-	-	35	74.5
A	80	5:1	2	42	78.1
B	80	10:1	2	28	75.6
C	100	5:1	2	73	85.3
D	100	10:1	2	56	83.5
E	100	15:1	2	126	86.1
F	100	10:1	4	246	90.7
G	120	5:1	2	87	84.2
H	120	10:1	2	76	83.8
I	150	5:1	2	189	88.6
J	150	10:1	2	106	85.1
K	200	5:1	2	59	74.2
L	200	10:1	2	48	72.8

Table 2. Mechanical properties of the as-printed CP-Ti modified powder and the unmodified, spherical Ti powder. Different laser powers were used for printing the modified Ti powder, denoted as A-D.

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Table 2. Mechanical properties of the as-printed CP-Ti modified powder and the unmodified, spherical Ti powder. Different laser powers were used for printing the modified Ti powder, denoted as A-D.

Material type	Laser power (W)	Hardness (HB)	Young's modulus (GPa)	Tensile strength (MPa)	Ductility (%)
Unmodified CP-Ti	110	214	94.9	695	16.25
Modified CP-Ti (A)	110	242	104.3	820	14.94
Modified CP-Ti (B)	120	249	106.6	895	18.99
Modified CP-Ti (C)	130	252	100.1	770	19.40
Modified CP-Ti (D)	140	246	101.3	860	15.93

Table 3. Powder flowability results of the modified and unmodified HDH Ti powders.
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Table 3. Powder flowability results of the modified and unmodified HDH Ti powders.
Powder Angle of repose (°) Flat corner (°) Crash angle (°) Tap density (g/cm³) Overall score
HDH-Ti 38.66 61.00 27.00 2.38 74.5
Modified 33.00 37.33 20.66 2.48 83.5

Table 4. Chemical compositions of the unmodified and modified HDH-Ti powder, and the as-printed Ti using the modified HDH-Ti and as-purchased spherical Ti powder.

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Table 4. Chemical compositions of the unmodified and modified HDH-Ti powder, and the as-printed Ti using the modified HDH-Ti and as-purchased spherical Ti powder.

	Mo (wt.%)	Cr (wt.%)	Ni (wt.%)	Mn (wt.%)	Fe (wt.%)	C (wt.%)	N (wt.%)	O (wt.%)
HDH-Ti	< 0.05	< 0.05	< 0.05	< 0.05	< 0.05	0.032	0.0069	0.218
Modified	< 0.05	0.019	0.028	< 0.05	0.07	0.044	0.0126	0.273
As-printed Ti	< 0.05	0.013	0.026	< 0.05	0.05	0.071	0.0130	0.330
Spherical Ti	-	-	-	-	0.02	0.020	0.020	0.150

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Yuhang Hou, Bin Liu, Yong Liu, Yinghao Zhou, Tingting Song, Qi Zhou, Gang Sha, Ming Yan. Ultra-low cost Ti powder for selective laser melting additive manufacturing and superior mechanical properties associated[J]. Opto-Electronic Advances, 2019, 2(5): 180028-1

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Paper Information

Category: Original Article

Received: Dec. 8, 2018

Accepted: Jan. 30, 2019

Published Online: Jun. 27, 2019

The Author Email: Ming Yan (yanm@sustc.edu.cn)

DOI:10.29026/oea.2019.180028

Topics

laser devices and laser physics

Lasers and Laser Optics

Laser physics

laser manufacturing

Instrumentation, Measurement and Metrology

Table 1. Particle size distribution, D50 and flowability score modified with different parameters. Parameter set No. D (underlined) shows the best combination of flowability and D50 values.

Table 1. Particle size distribution, D50 and flowability score modified with different parameters. Parameter set No. D (underlined) shows the best combination of flowability and D50 values.

Table 2. Mechanical properties of the as-printed CP-Ti modified powder and the unmodified, spherical Ti powder. Different laser powers were used for printing the modified Ti powder, denoted as A-D.

Table 2. Mechanical properties of the as-printed CP-Ti modified powder and the unmodified, spherical Ti powder. Different laser powers were used for printing the modified Ti powder, denoted as A-D.

Table 3. Powder flowability results of the modified and unmodified HDH Ti powders.

Table 3. Powder flowability results of the modified and unmodified HDH Ti powders.

Table 4. Chemical compositions of the unmodified and modified HDH-Ti powder, and the as-printed Ti using the modified HDH-Ti and as-purchased spherical Ti powder.

Table 4. Chemical compositions of the unmodified and modified HDH-Ti powder, and the as-printed Ti using the modified HDH-Ti and as-purchased spherical Ti powder.