Fabrication of Spherical AlSi10Mg Powders by Radio Frequency Plasma Spheroidization
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HYPEREUTECTIC AlSi10Mg alloys are used widely in automotive industry, electronic components, medical devices, sports equipment and other industrial applications because of their unique performance, such as low density, good fluidity, relatively high strength, excellent corrosion resistance and nonmagnetic properties.[1] Recently, the rapid development of additive manufacturing,[2] powder injection molding,[3] laser forming,[4] warm flow compaction[5] and thermal spraying technology[6] demand tougher properties of the AlSi10Mg powder, such as more uniform particle size and higher sphericity flowability. However, it is difficult for commercial AlSi10Mg powder to achieve these requirements due to its low flowability caused by irregular shape. Hence, it is important to study the preparation technology of spherical AlSi10Mg powders in order to accelerate the applications of them. At present, preparation methods of powders mainly include mechanical grinding, self propagating high-temperature synthesis, atomization, rotating electrode processing, and so on. Mechanical grinding method has advantages of simple process and low cost, but its lower efficiency and purity limit the large-scale industrialized production.[7] Although self-propagating high-temperLINZHI WANG, Assistant Researcher, is with the College of Material Science and Engineering, Sichuan University, Chengdu 610065 P.R. China, and also with the Chongqing Key Laboratory of Multi-Scale Manufacturing Technology, Chongqing Institute of Green and Intelligent Technology, Chinese Academy of Sciences, Chongqing 400714 P.R. China. YING LIU, Professor, is with the College of Material Science and Engineering, Sichuan University. Contact e-mail: [email protected] SEN CHANG, Engineer, is with Changzhi Qinghua Machinery Factory, Changzhi 046000, P.R. China. Manuscript submitted July 14, 2015. Article published online February 22, 2016 2444—VOLUME 47A, MAY 2016
ature synthesis process is simple, its drawbacks are higher oxygen content, irregular shape, and inhomogeneous composition for powders.[8] Powders with spherical shapes, good fluidity, and low oxygen contents can be prepared by atomization. However, the production cost is relatively high; especially, the purity of the powder is poor because of the contamination of crucible.[9] Rotary electrode processing method can manufacture metal powder with high purity, but average particle size of the powders usually exceeds 150 lm. Recently, because of high temperature, high reactivity, minimum contamination, and large plasma volume,[10–13] radio frequency (RF) plasma spheroidization technology has been used widely to prepare spherical powders with uniform composition, high sphericity, and excellent flowability. However, the influences of the spheroidization process parameters on morphologies, particle size distribution, microstructures, flowability, and laser absorption properties of the AlSi10Mg powders are still an open question yet unresolved. Therefore, in this study, the morphologies and particle size distributions under diffe
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