Implementation of Twin Wire-Arc Spray as a Promising method for production of 316 SS powders for Additive Manufacturing Applications

This study investigates the potential of Twin Wire-Arc Spray (TWAS) as a method for producing 316 stainless steel (SS) powders optimized for additive manufacturing (AM) applications. Particle size distribution (PSD) analysis confirmed a D50 of 57.55 μm, well within the range required for powder bed fusion AM. Over 95% of the powders exhibited high sphericity, as shown through scanning electron microscopy, enhancing their flowability-an essential trait for AM. Vickers hardness measurements revealed that the 316 SS powders produced by TWAS achieved a significantly higher hardness (384 HV) compared to conventional gas-atomized powders (273 HV), highlighting the high cooling rate of this process. Microstructural analysis of solidification behavior identified diverse structural formations, from dendritic to cellular to planar, corresponding to variations in cooling rates. Additionally, the presence of chromium in the powders contributed to a protective oxide layer, reducing porosity and enhancing corrosion resistance, both vital for AM applications. These findings underscore the suitability of TWAS for producing 316 SS powders with the structural and mechanical properties desired for powder bed fusion additive manufacturing.

Implementation of Twin Wire-Arc Spray as a Promising method for production of 316 SS powders for Additive Manufacturing Applications Keywords:

Powder production , Twin wire-arc spray , 316 stainless steel , Surface oxidation