Development of particle surface modification and reinforcement transplant and additive manufacturing of metal matrix composites

Abstract

Metal additive manufacturing, also known as 3D printing, is gaining significant attention in academia and advanced industries as a next-generation production process for complex metal products. However, the limited availability of suitable materials restricts the freedom to achieve desired properties. To address this issue, there is a need for the development of new materials specifically designed for metal additive manufacturing. Unfortunately, the conventional powder manufacturing method, which relies on atomization, is not effective for the exploration of new materials. To overcome this challenge, an alternative approach is required for manufacturing raw material powders. However, the existing attempts failed to meet the performance requirements for additive manufacturing, resulting in compromised additive manufacturing capabilities. Therefore, the development of a new concept of powders and production technology becomes imperative. In this study, a novel technique called ‘Surface Modification And Reinforcement Transplant (SMART)’ was developed for precise control of powders used in additive manufacturing. The SMART technology enables precise control of powder surfaces through momentum adjustment, allowing for processes such as spheroidization, coating, alloying, and reinforcing material implantation. This innovative approach facilitates the rapid production of new material powders for metal additive manufacturing, particularly composite powders. By utilizing the SMART process, alloy and composite material powders were successfully produced and employed in additive manufacturing processes. The additive manufacturing behavior of the composites was analyzed and compared with traditional casting and powder metallurgy methods, revealing the complementary nature of composite concepts and additive manufacturing. Through this research, a solution was provided for the challenges associated with the production of high-performance complex-shaped products and the additive manufacturing of alloys.