Slurry preparation for semi-solid metal direct writing by a novel approach of mixed powder remelting

Z. Li; X.G. Hu; W.Y. Qu; Y. Zhou; C Guo; H.X. Lu; X.X. M; I. Mohagheghian; M. J. Whiting; Q. Zhu

doi:10.1016/j.powtec.2023.118673

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Slurry preparation for semi-solid metal direct writing by a novel approach of mixed powder remelting

Journal article

Peer reviewed

Slurry preparation for semi-solid metal direct writing by a novel approach of mixed powder remelting

Z. Li, X.G. Hu, W.Y. Qu, Y. Zhou, C Guo, H.X. Lu, X.X. M, I. Mohagheghian, M. J. Whiting and Q. Zhu

Powder Technology, Vol.426, 118673

01/08/2023

DOI: https://doi.org/10.1016/j.powtec.2023.118673

Abstract

Aluminum alloys

Metal direct writing

Semi-solid processing

Shape factor

Solid fraction

Extrusion-based metal direct writing is a promising metal additive manufacturing technology due to its high efficiency and low cost. However, fabricating parts with high integrity and complex geometry remains challenging. The most critical factor is the unavailable of semi-solid slurries with uniform and nearly spherical solid particles, resulting in uncontrollable extrusion and printing. Currently, mixed powder remelting (MPR) is reported to preset the features of the solid phases, including volume fraction, morphology, and size distribution. Specifically, the semi-solid slurries of hypoeutectic AlSi alloys were obtained by preheating and shearing the mixed powder composed of eutectic AlSi alloy powder and pure aluminum powder. Their microstructural characteristics and rheological behavior were investigated, demonstrating the microstructure tailoring (controllable solid fraction and size distribution, high shape factor of about 0.9) and the reduced viscosity fluctuation by a factor of 7 compared with traditional processes. MPR shows unparalleled advantages for further engineering applications of metal direct writing.

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Title: Slurry preparation for semi-solid metal direct writing by a novel approach of mixed powder remelting
Creators: Z. Li (Author) - Department of Mechanical and Energy Engineering, Southern University of Science and Technology, Shenzhen 518055, China
X.G. Hu (Corresponding Author) - Department of Mechanical and Energy Engineering, Southern University of Science and Technology, Shenzhen 518055, China
W.Y. Qu (Author) - BYD Auto Industry Company Limited, Shenzhen 518118, China
Y. Zhou (Author) - Department of Mechanical and Energy Engineering, Southern University of Science and Technology, Shenzhen 518055, China
C Guo (Author) - Shenzhen Key Laboratory for Additive Manufacturing of High-performance materials, Southern University of Science and Technology, Shenzhen 518055, China
H.X. Lu (Author) - Department of Mechanical and Energy Engineering, Southern University of Science and Technology, Shenzhen 518055, China
X.X. M (Author) - Department of Mechanical and Energy Engineering, Southern University of Science and Technology, Shenzhen 518055, China
I. Mohagheghian (Author) - University of Surrey, Department of Mechanical Engineering Sciences
M. J. Whiting (Author) - Department of Mechanical Engineering Sciences, University of Surrey, Guildford, Surrey GU2 7XH, UK
Q. Zhu (Corresponding Author) - Department of Mechanical and Energy Engineering, Southern University of Science and Technology, Shenzhen 518055, China
Publication Details: Powder Technology, Vol.426, 118673
Publisher: Elsevier
Date published: 01/08/2023
Date accepted: 18/05/2023
Grant note: This work was financially supported by the National Natural Science Foundation of China (Grant numbers 51805238, 52250710160), Shenzhen Science and Technology Innovation Committee, Shenzhen, China [Grant numbers KQTD20170328154443162, JCYJ20210324104610029, JCYJ20220818100613028].
Identifiers: 99792466502346
Academic Unit: Department of Mechanical Engineering Sciences
Language: English
Resource Type: Journal article
SDG (Scopus 2023): SDG 9

Slurry preparation for semi-solid metal direct writing by a novel approach of mixed powder remelting

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