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Powder Characterization for Additive Manufacturing Processes
Luleå University of Technology, Department of Engineering Sciences and Mathematics.
2017 (English)Independent thesis Basic level (professional degree), 20 credits / 30 HE creditsStudent thesisAlternative title
Pulverkarakterisering för Additiva Tillverkningsprocesser (Swedish)
Abstract [en]

The aim of this master thesis project was to statistically correlate various powder characteristics to the quality of additively manufactured parts. An additional goal of this project was to find a potential second source supplier of powder for GKN Aerospace Sweden in Trollhättan. Five Inconel® alloy 718 powders from four individual powder suppliers have been analyzed in this project regarding powder characteristics such as: morphology, porosity, size distribution, flowability and bulk properties. One powder out of the five, Powder C, is currently used in production at GKN and functions as a reference. The five powders were additively manufactured by the process of laser metal deposition according to a pre-programmed model utilized at GKN Aerospace Sweden in Trollhättan. Five plates were produced per powder and each cut to obtain three area sections to analyze, giving a total of fifteen area sections per powder. The quality of deposited parts was assessed by means of their porosity content, powder efficiency, geometry and microstructure. The final step was to statistically evaluate the results through the analysis methods of Analysis of Variance (ANOVA) and simple linear regression with the software Minitab.

The method of ANOVA found a statistical significant difference between the five powders regarding their experimental results. This made it possible to compare the five powders against each other. Statistical correlations by simple linear regression analysis were found between various powder characteristics and quality of deposited part. This led to the conclusion that GKN should consider additions to current powder material specification by powder characteristics such as: particle morphology, powder porosity and flowability measurements by a rheometer.

One powder was found to have the potential of becoming a second source supplier to GKN, namely Powder A. Powder A had overall good powder properties such as smooth and spherical particles, high particle density at 99,94% and good flowability. The deposited parts with Powder A also showed the lowest amount of pores compared to Powder C, a total of 78 in all five plates, and sufficient powder efficiency at 81,6%.

Place, publisher, year, edition, pages
2017. , p. 117
Keywords [en]
Powder Characterization, Inconel 718, Additive Manufacturing, Laser Metal Deposition, ANOVA, Regression Analysis
National Category
Materials Engineering
Identifiers
URN: urn:nbn:se:ltu:diva-62683OAI: oai:DiVA.org:ltu-62683DiVA, id: diva2:1084670
External cooperation
GKN Aerospace Sweden
Educational program
Materials Engineering, master's level
Supervisors
Examiners
Available from: 2017-05-10 Created: 2017-03-27 Last updated: 2017-05-10Bibliographically approved

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CiteExportLink to record
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Citation style
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