The Paton Welding Journal, 2023, №12



2023 №12 (06)

DOI of Article 10.37434/tpwj2023.12.01

2023 №12 (02)

---

The Paton Welding Journal, 2023, #12, 3-18 pages

Development of plasma-arc technologies of spherical granules production for additive manufacturing and powder metallurgy

V.M. Korzhyk, D.V. Strohonov, O.M. Burlachenko, O.M. Voitenko, D.V. Kunitskyi

E.O. Paton Electric Welding Institute of the NASU.. 11 Kazymyr Malevych Str., 03150, Kyiv, Ukraine. E-mail: vnkorzhyk@gmail.com

Abstract
The technological and structural properties of spherical granules and the peculiarities of their production processes using industrial technologies of gas atomization, plasma rotating electrode process and plasma‑arc atomization of neutral and current‑carrying wires and rods are considered. It was found that among the considered methods of obtaining spherical granules, the most promising in terms of productivity, energy efficiency and simplicity of the equipment used is the method of plasma‑arc atomization, which, due to the presence of a large number of technological and structural parameters of the process, allows adjusting the particles size distribution and technological properties of the granules in a wide range. Experimental studies have shown that the particles size distribution, shape factor and technological properties of granules made of titanium alloys and stainless steel obtained by plasma‑arc atomization of current‑carrying wire materials at the E.O. Paton Electric Welding Institute of the NAS of Ukraine, together with LLC «R&D PLAZER center», are at the level of the best foreign analogues. A promising direction of increasing the energy efficiency and productivity of the process of obtaining spherical granules for additive manufacturing and granule metallurgy using the technology of plasma‑arc atomization of current‑carrying rods with a diameter of more than 50 mm at reversed polarity by plasma torches with a hollow copper anode is proposed. Ref. 29, Tabl. 4, Fig. 20.
Keywords: plasma-arc atomization of current-carrying wires and rods, spherical granules, additive manufacturing, selective and direct laser melting, granule metallurgy

Received: 19.10.2023
Accepted: 26.12.2023

References

1. Iliyushchenko, A.F., Savich, V.V. (2017) History and state-of-theart of additive technologies in Belarus, powders of metals and alloys for them. Kosmichna Nauka i Tekhnologiya, 23(4), 33-45. [in Russian]. https://doi.org/10.15407/knit2017.04.033
2. Singh, D.D., Mahender, T., Reddy, A.R. (2021) Powder bed fusion process: A brief review. Materials Today: Proceedings, 46(1), 350-355. https://doi.org/10.1016/j.matpr.2020.08.415
3. Ahn, D.G. (2021) Directed Energy Deposition (DED) Process: State of the Art. Int. J. of Precis. Eng. and Manuf. - Green Tech., 8, 703-742. https://doi.org/10.1007/s40684-020-00302-7
4. Anderson, I.E. et al. (2018) Feedstock powder processing research needs for additive manufacturing development. Curr. Opin. Solid State Mater. Sci., 22(1), 8-15. https://doi.org/10.1016/j.cossms.2018.01.002
5. Chen, G., Zhao, S.Y., Tan, P. et al. (2018) A comparative study of Ti-6Al-4V powders for additive manufacturing by gas atomization, plasma rotating electrode process and plasma atomization. Powder Technology, 333, 38-46. https://doi.org/10.1016/j.powtec.2018.04.013
6. Sun, P., Fang, Z., Zhang, Y. et al. (2017) Review of the methods for the production of spherical Ti and Ti alloy powder. JOM, 69, 1853-1860. https://doi.org/10.1007/s11837-017-2513-5
7. Heidloff, A.J., Rieken, J.R., Anderson, I.E. et al. (2010) Advanced gas atomization processing for Ti and Ti alloy powder manufacturing. JOM, 62, 35-41. https://doi.org/10.1007/s11837-010-0075-x
8. Guo, K., Liu, C., Chen, S. et al. (2020) High pressure EIGA preparation and 3D printing capability of Ti-6Al-4V powder. Transactions of Nonferrous Metals Society of China, 30(1), 147- 159. https://doi.org/10.1016/S1003-6326(19)65187-3
9. Martín, A., Cepeda-Jiménez, C.M., Pérez-Prado, M.T. (2020) Gas atomization of γ-TiAl alloy powder for additive manufacturing. Adv. Eng. Mater., 22, 1900594. https://doi.org/10.1002/adem.201900594
10. Drawin, S., Deborde, A., Thomas, M. et al. (2020) Atomization of Ti-64 alloy using the EIGA process: comparison of the characteristics of powders produced in labscale and industrial-scale facilities. MATEC Web Conf., 321, 07013. https://doi.org/10.1051/matecconf/202032107013
11. Zhong, C., Chen, J., Linnenbrink, S. et al. (2016) A comparative study of Inconel 718 formed by high deposition rate laser metal deposition with GA powder and PREP powder. Materials & Design, 107, 386-392. https://doi.org/10.1016/j.matdes.2016.06.037
12. Zhao, Y., Cui, Y., Numata, H. et al. (2020) Centrifugal granulation behavior in metallic powder fabrication by plasma rotating electrode process. Sci. Rep., 10, 18446. https://doi.org/10.1038/s41598-020-75503-w
13. Yang Liu, Xiao-hao Zhao, Yun-jin Lai et al. (2020) A brief introduction to the selective laser melting of Ti6Al4V powders by supreme-speed plasma rotating electrode process. Progress in Natural Science: Materials International, 30(1), 94-99. https://doi.org/10.1016/j.pnsc.2019.12.004
14. Strogonov, D.V., Korzhyk,V.M., Jianglong Ti, et al. (2022) Influence of the parameters of the process of plasma-arc spheroidization of current-conducting wire from low-carbon steel on the granulometric composition of the produced powders. Suchasna Elektrometal., 3, 29-38 [in Ukrainian]. https://doi.org/10.37434/tpwj2022.09.09
15. Yurtkuran, E., Ünal, R. (2022) Theoretical and experimental investigation of Ti alloy powder production using low-power plasma torches. Transactions of Nonferrous Metals Society of China, 32(1), 175-191. https://doi.org/10.1016/S1003-6326(21)65786-2
16. Tsantrizos, P.G, Allaire, F., Entezarian, M. (1998) Method of production of metal and ceramic powders by plasma atomization. US patent, 5707419 [P], 1998−01−13.
17. Cacace, S., Boccadoro, M., Semeraro, Q. (2023) Investigation on the effect of the gas-to-metal ratio on powder properties and PBF-LB/M processability. Prog. Addit. Manuf. https://doi.org/10.1007/s40964-023-00490-z
18. Korzhyk, V.M., Strogonov, D.V., Burlachenko, O.M. et al. (2023) New generation unit for plasma-arc deposition of coatings and spraying of current-conducting wire materials. Suchasna Elektrometal., 3, 19-27 [in Ukrainian]. https://doi.org/10.37434/sem2020.03
19. Korzhyk, V.M., Strogonov, D.V., Burlachenko, O.M. et al. (2023) Effectiveness of the process of plasmaarc spheroidization of current-conducting titanium wire. Suchasna Elektrometal., 1, 1-9 [in Ukrainian]. https://doi.org/10.37434/tpwj2023.03.05
20. Capus, J. (2017) AP&C: moving fast with the rise of AM. Metal Powder Report, 72(1), 22-24. https://doi.org/10.1016/j.mprp.2016.12.001
21. Petrunichev, V.A., Kudinov, V.V., Kulagin, I.D. (1965) Production of spheroidized metal powder by wire spraying. Metally, 2, 68-94 [in Russian].
22. Zelenin, V.I., Kavunenko, P.M., Tisenkov, V.V. et al. (2009) Application of plasma-arc metallization for restoration of wheel pairs. The Paton Welding J., 12, 28-31.
23. Korzhik, V.N., Korob,M.F. (2012) Mechanized line PLAZER 30PL-W for plasma-arc wire spraying of coatings on largesized parts of "shaft" type. Svarshchik, 4, 13-15 [in Russian].
24. Kharlamov, M.Yu., Krivtsun, I.V., Korzhik, V.N. et al. (2008) Effect of the type of concurrent gas flow on characteristics of the arc plasma generated by plasmatron with anode wire. The Paton Welding J., 6, 14-18.
25. Kharlamov, M., Krivtsun, I., Korzhyk, V., Demyanov, O. (2015) Simulation of motion, heating and breakup of molten metal droplets in the plasma jet at plasma-arc spraying. J. of Thermal Spray Technology, 24, 659-670. https://doi.org/10.1007/s11666-015-0216-4
26. Liu, F., Yu, D., Zhang, Q. et al. (2023) Experimental and numerical analysis of a novel reverse-polarity plasma torch with transferred arc hot-wall nozzle for atmospheric plasma spraying of YSZ coatings. Surface and Coatings Technology, 459, 129413. https://doi.org/10.1016/j.surfcoat.2023.129413
27. Shchitsyn, V.Yu., Yazovskikh, V.M. (2009) Effect of polarity on the heat input into the nozzle of a plasma torch, Welding International, 16(6), 485-487. https://doi.org/10.1080/09507110209549563
28. Kharlamov, M.Yu., Krivtsun, I.V., Korzhik, V.N. et al. (2015) Modelling the characteristics of constricted-arc plasma in straight and reverse polarity air-plasma cutting. The Paton Welding J., 10, 10-18. https://doi.org/10.15407/tpwj2015.10.02
29. Bouabbou, A., Vaudreuil, S. (2023) Numerical modelling of SS316L powder flowability for laser powderbed fusion. Archives of Materials Science and Engineering, 120(1), 22- 29. https://doi.org/10.5604/01.3001.0053.6014

---

Suggested Citation

V.M. Korzhyk, D.V. Strohonov, O.M. Burlachenko, O.M. Voitenko, D.V. Kunitskyi (2023) Development of plasma-arc technologies of spherical granules production for additive manufacturing and powder metallurgy. The Paton Welding J., 12, 3-18.

---