Evaluating the feeding of water atomized powder for additive manufacturing

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Additive manufacturing is maturing and as it does we are faced with major challenges that continue to limit its wider adoption. In the case of powder-based metallic additive manufacturing a significant financial hurdle comes from the cost of the metallic powder that must be used. Gas atomized powders with a highly spherical shape are needed in traditional powder feeding systems due to the risk of clogging that arises with more irregularly shaped powders. Gas atomized powders are, however, significantly more expensive compared to powders more traditionally used in high volume processes such as powder metallurgy.In this project, we seek to investigate the potential of a new technology for the feeding of metallic powders in additive manufacturing. To date, gas atomized powders have been successfully fed using this new powder feeder. To investigate the potential of this new technology to also feed more irregularly shaped (but significantly lower cost) water atomized powders, we propose to partner with Canadian company Rio Tinto Metal Powders. Irregularly shaped steel powders, used in powder metallurgy, having different size distributions and compositions will be evaluated within our feeding system. Optimal parameters for feeding will be established and compared with the results of numerical (discrete element modelling) results. The aim is to show that many of the current concerns over the use of water atomized powder can be eliminated if new technologies for powder feeding can be introduced to the field.