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Why is powder feedstock for metal AM so expensive?

27/4/2018

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Regardless of procurement route, research shows that metal powder costs will be the biggest continuous expense through the life of an AM machine. Let’s have a look at the reasons behind the high-costs of metal powder feedstock.


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How to avoid powder contamination in AM

23/3/2018

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powder produced via (a, b) Gas atomisation; (c, d) rotary atomisation; (d, e) plasma rotating electrode process [1]
The powder chain goes hand-in-hand with the AM processing chain. It is a reciprocal and interdependent relationship whereby powder properties impact on the processing characteristics (spreading, melting…) and where, in return, the processing steps and efficiency affect the powder characteristics.
This close intertwined relationship complicate the control of the AM process and  can dramatically influence the final components properties or the recyclability efficiency of the powder.
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So how do you prevent powder contamination or properties variations?

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Customers considerations for metal AM powder procurement

16/3/2018

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Materials sales for AM machines worldwide [2]
Metal powder costs will be the biggest continuous expense through the life of an AM machine [1]. Under these circumstances, a customer has a number of considerations to make when defining powder requirements and deciding where to procure it.

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Post-build healing of pores in metal AM: is HIP efficient?

9/3/2018

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micro-XCT reconstruction of Ti-6Al-4V powder with porosity trapped within powder particles shown in red [1]
​Post-build hot iso-static pressing (HIP) has become a common practice for the closure of some types of defects in AM metal components. Assuming your products lend themselves to HIPing, can this post-processing method get rid of all porosity?

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Particles properties inducing porosity in metal AM

2/3/2018

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Images of gas atomized MAR-M-247 powder, sample1, size range: 45–106um [ref 15]
Some defects found in parts built using AM are related to processing parameters or to the composition of alloys optimised for more conventional, slow-cooling manufacturing process. These defects – such as porosity or cracking – can sometimes be healed by post-processing such as hot isostatic pressing (HIP). Yet, the formation of pores during AM is also linked to the quality of virgin powder.

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