Optimizing the rheology of metal powder feedstock for the production of high-density components by powder metallurgy, additive manufacturing and metal injection molding techniques

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This project aims at evaluating the suitability of the advanced rheology-based measurement techniques for the improvement of flowability of water-atomized metallic powders and powder mixtures. These powders and powder mixtures serve as a feedstock for rapidly developing advanced manufacturing processes, such as the high processing speed compaction (PM), additive manufacturing via the laser powder-bed fusion and the binder-jetting techniques (AM), and the metal injection molding (MIM). The improvement of flow properties of these powders and powder mixture will allow fabrication of high performance products for transport and energy.Furthermore, the realization of this project will position our industrial partner as one of the largest suppliers of cost-effective steel powders to Canadian companies which turn towards PM, AM and MIM technologies with the objective to augment their overall competitiveness.A combination of cost-effective water-atomized powders with an improved buy-to-fly ratio and high in-process powder recycling rate of PM/AM/MIM manufacturing technologies would benefit both the industry and the environment.Finally, this research project will contribute to form highly qualified technical personnel trained in the fields of materials science and advanced manufacturing to satisfy the ever-growing demand from Canadian manufacturing industry.