The objective of this work is to study the possibility of obtaining dense parts using water atomized AISI 316L steel powder in the L-PBF process. Despite its irregular, non-spherical, particle morphology, it has a significantly lower cost. 25 samples were produced varying the laser power and the scanning speeds to determine the optimal processing conditions. Additionally, hot isostatic pressing (HIP) was performed after the L-PBF process to further increase densification. Selected samples were subjected to microstructural characterization. The best densification results obtained were for the sample produced with the laser power of 173 W and scanning speed of 600 mm/s, where densifications close to 98% were obtained. HIP post-processing promoted increased densification of samples with closed porosity, allowing samples with densification above 95% to reach values close to 100%. HIP did not promote the closure of open pores. The results indicate that the use of water atomized AISI 316L in the L-PBF process combined with post-processing by HIP can produce dense engineering components and at the same time reduce the production costs of the manufactured components, mainly because it is a lower cost raw material when compared to the commonly used feedstock obtained by gas atomization.

Abstract The effect of temperature was investigated on the consolidation of blended elemental powders of aluminum and copper by equal channel angular pressing (ECAP). Aluminum and Copper powders (1:1% vol.) were blended and consolidated in a 90° ECAP die at room (RT) and cryogenic temperatures (CT - ~77 K). ECAP samples were pressed until 4 passes at room temperature in route Bc. As a reference, a sample was obtained by conventional uniaxial pressing. The obtained results indicated a much denser (>99.5%) and harder structure by cryogenic ECAP. The hardness after one pass at CT was comparable with 4 passes at room temperature. Tensile tests performed at CT for materials with similar chemical composition showed a simultaneous increase in strength and ductility at CT, corroborating the results obtained by ECAP. The partial suppression of dynamic recovery and the activation and the transition between deformation mechanisms at CT, as well as stacking fault energies (SFE) of such metals, played an important role in these results. Copper presented a much higher capability of strain hardening than aluminum, due to its lower SFE and much lower homologous temperature. X-ray diffraction indicated a strong correlation between the variation of average microstrain and the variation of hardness on both metals. The results of this study demonstrated the great potential of the application of very low temperatures for the obtaining of deformation metal-metal composites.

ABSTRACT Doping polymers with metallic materials can improve significantly its use. Ultra high molecular weight polyethylene is known for its high resistance to abrasion and impact, and also for its friction coefficient, which is significantly lower than that of commercial steel and most polymeric materials. Therefore, this material presents high industrial demand despite its processing difficulty due to its high viscosity. One kind of polymer processing which has been widely used recently is the high energy mechanical alloying. This method provokes significant changes in the material, such as crystalline structure transformation, amorphization, formation of metastable phases, and nanostructuring, among others. In order to investigate the influence of iron dopant in structural characteristics of polymeric matrix, ultra high molecular weight polyethylene were doped with low concentrations (between 0.1 at.% and 1 at.%) of iron using the method of high energy mechanical alloying. The samples composition was characterized by X-Ray Diffraction Mössbauer Spectroscopy. A theoretical molecular modeling was carried out to simulate the iron presence in polymeric cell, which is in good agreement with the experimental results. Therefore, there is evidence that part of the iron promotes a crossed bond between the polymeric chains.

Equal channel angular pressing (ECAP) is one of the severe plastic deformation processes that can also be used for metallic powder consolidation. Consolidation of blended elemental powders of iron, chromium, nickel, and manganese (Fe-25Cr-20Ni-2Mn wt. %) was performed at room temperature in a Φ = 120° die by 1 and 2 passes. SEM micrographs indicated that single pass ECAP consolidated sample presented close to full densification. Additional pass of ECAP led to hardness increase and to an apparent better mixing between the different particles. SEM/EDX analysis made before and after heat treatment of the samples showed that effective diffusion only took place after heat treatment and especially in the sample subjected to 2 ECAP passes. Results indicate that alloying by ECAP consolidation and posterior heat treatment is feasible, especially for systems that cannot be processed by conventional means, as well as mechanical alloying.

Aluminum, copper and silver samples, all of them face-centered cubic (FCC) metals, were rolled at room and cryogenic temperatures until equivalent strains (ε) were between 3.23 and 4.13. The cryogenic temperature (CT) and room temperature (RT) rolled samples were evaluated by hardness tests and X-ray diffraction (XRD), which indicate influence of stacking fault energy (SFE) on process. Lower SFE metals tend to exhibit dislocation densities significantly increased and as consequence, hardness too. It was also noted that after sometime exposed to RT, the materials rolled at CT present hardness decrease.