Production of S7 tool steel powders by water atomization for laser powder bed fusion and directed energy deposition additive manufacturing
The vast majority of powders used in additive manufacturing (AM) are produced by gas atomization. This process generates metal powders typically made of spherical particles that are exempt from significant oxidation products. The objective of the work summarized in this article is to substitute gas...
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Elsevier
2025-06-01
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| Series: | Materials & Design |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S0264127525005271 |
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| author | Denis Mutel Simon Gélinas Carl Blais |
| author_facet | Denis Mutel Simon Gélinas Carl Blais |
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| description | The vast majority of powders used in additive manufacturing (AM) are produced by gas atomization. This process generates metal powders typically made of spherical particles that are exempt from significant oxidation products. The objective of the work summarized in this article is to substitute gas atomization with water atomization to produce steel powders for additive manufacturing. Due to their irregular morphology, water-atomized metal particles are well known for having significantly lower apparent density and flowability than gas-atomized ones. The rationale of this study is to optimize the chemistry of the original alloys in combination with post-sintering treatments to maximize particle sphericity (morphology) while minimizing oxygen content. Results show that tool steel powders having rheological properties close to those of gas-atomized powders can be produced by water atomization, making them adequate for additive manufacturing in laser powder bed fusion and directed energy deposition These results suggest that water-atomized metal powders are a serious alternative to gas-atomized powders. It becomes clear that water-atomized steel powders can drive greater adoption of additive manufacturing for high-volume production of ferrous components. |
| format | Article |
| id | doaj-art-df2e36f5e1a94c47aecc32e5aa972d25 |
| institution | OA Journals |
| issn | 0264-1275 |
| language | English |
| publishDate | 2025-06-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Materials & Design |
| spelling | doaj-art-df2e36f5e1a94c47aecc32e5aa972d252025-08-20T02:09:11ZengElsevierMaterials & Design0264-12752025-06-0125411410710.1016/j.matdes.2025.114107Production of S7 tool steel powders by water atomization for laser powder bed fusion and directed energy deposition additive manufacturingDenis Mutel0Simon Gélinas1Carl Blais2Powder Metallurgy Laboratory, Department of Mining, Metallurgical & Materials Engineering, Université Laval, 1065 de la médecine, Québec, QC G1V 0A6, CanadaPowder Metallurgy Laboratory, Department of Mining, Metallurgical & Materials Engineering, Université Laval, 1065 de la médecine, Québec, QC G1V 0A6, CanadaCorresponding author.; Powder Metallurgy Laboratory, Department of Mining, Metallurgical & Materials Engineering, Université Laval, 1065 de la médecine, Québec, QC G1V 0A6, CanadaThe vast majority of powders used in additive manufacturing (AM) are produced by gas atomization. This process generates metal powders typically made of spherical particles that are exempt from significant oxidation products. The objective of the work summarized in this article is to substitute gas atomization with water atomization to produce steel powders for additive manufacturing. Due to their irregular morphology, water-atomized metal particles are well known for having significantly lower apparent density and flowability than gas-atomized ones. The rationale of this study is to optimize the chemistry of the original alloys in combination with post-sintering treatments to maximize particle sphericity (morphology) while minimizing oxygen content. Results show that tool steel powders having rheological properties close to those of gas-atomized powders can be produced by water atomization, making them adequate for additive manufacturing in laser powder bed fusion and directed energy deposition These results suggest that water-atomized metal powders are a serious alternative to gas-atomized powders. It becomes clear that water-atomized steel powders can drive greater adoption of additive manufacturing for high-volume production of ferrous components.http://www.sciencedirect.com/science/article/pii/S0264127525005271Water atomizationSteel powdersAdditive manufacturingLaser Powder-Bed FusionDirected Energy Deposition |
| spellingShingle | Denis Mutel Simon Gélinas Carl Blais Production of S7 tool steel powders by water atomization for laser powder bed fusion and directed energy deposition additive manufacturing Materials & Design Water atomization Steel powders Additive manufacturing Laser Powder-Bed Fusion Directed Energy Deposition |
| title | Production of S7 tool steel powders by water atomization for laser powder bed fusion and directed energy deposition additive manufacturing |
| title_full | Production of S7 tool steel powders by water atomization for laser powder bed fusion and directed energy deposition additive manufacturing |
| title_fullStr | Production of S7 tool steel powders by water atomization for laser powder bed fusion and directed energy deposition additive manufacturing |
| title_full_unstemmed | Production of S7 tool steel powders by water atomization for laser powder bed fusion and directed energy deposition additive manufacturing |
| title_short | Production of S7 tool steel powders by water atomization for laser powder bed fusion and directed energy deposition additive manufacturing |
| title_sort | production of s7 tool steel powders by water atomization for laser powder bed fusion and directed energy deposition additive manufacturing |
| topic | Water atomization Steel powders Additive manufacturing Laser Powder-Bed Fusion Directed Energy Deposition |
| url | http://www.sciencedirect.com/science/article/pii/S0264127525005271 |
| work_keys_str_mv | AT denismutel productionofs7toolsteelpowdersbywateratomizationforlaserpowderbedfusionanddirectedenergydepositionadditivemanufacturing AT simongelinas productionofs7toolsteelpowdersbywateratomizationforlaserpowderbedfusionanddirectedenergydepositionadditivemanufacturing AT carlblais productionofs7toolsteelpowdersbywateratomizationforlaserpowderbedfusionanddirectedenergydepositionadditivemanufacturing |