In this study, AlSi10Mg alloy powders are synthesized using gas atomization and sieving processes for powder bed fusion (PBF) additive manufacturing. The effect of nozzle diameter (ø = 4.0, 4.5, 5.0 and 8.0 mm) on the gas atomization and sieving size on the properties of the prepared powder are investigated. As the nozzle diameter decreases, the size of the manufactured powder decreases, and the uniformity of the particle size distribution improves. Therefore, the ø 4.0 mm nozzle diameter yields powder with superior properties. Spherically shaped powders can be prepared at a scale suitable for the PBF process with a particle size distribution of 10–45 μm. The Hausner ratio value of the powder is measured to be 1.24. In addition, the yield fraction of the powder prepared in this study is 26.6%, which is higher than the previously reported value of 10–15%. These results indicate that the nozzle diameter and the post-sieve process simultaneously influence the shape of the prepared powder as well as the satellite powder on its surface.

In this study, ultra-fine soft-magnetic micro-powders are prepared by high-pressure gas atomization of an Fe-based alloy, Fe-Hf-B-Nb-P-C. Spherical powders are successfully obtained by disintegration of the alloy melts under high-pressure He or N2 gas. The mean particle diameter of the obtained powders is 25.7 μm and 42.1 μm for He and N2 gas, respectively. Their crystallographic structure is confirmed to be amorphous throughout the interior when the particle diameter is less than 45 μm. The prepared powders show excellent soft magnetic properties with a saturation magnetization of 164.5 emu/g and a coercivity of 9.0 Oe. Finally, a toroidal core is fabricated for measuring the magnetic permeability, and a μr of up to 78.5 is obtained. It is strongly believed that soft magnetic powders prepared by gas atomization will be beneficial in the fabrication of high-performance devices, including inductors and motors.

Microstructure evolutions of thermosetting resin coating layers fabricated by electrostatic spray deposition (ESD) at various processing conditions were investigated. Two different typical polymer systems, a thermosetting phenol-formaldehyde resin and a thermoplastic polyvinylpyrrolidone (PVP), were employed for a comparative study. Precursor solutions of the phenol-formaldehyde resin and of the PVP were electro-sprayed on heated silicon substrates. Fundamental differences in the thermomechanical properties of the polymers resulted in distinct ways of microstructure evolution of the electro-sprayed polymer films. For the thermosetting polymer, phenol-formaldehyde resin, vertically aligned micro-rod structures developed when it was deposited by ESD under controlled processing conditions. Through extensive microstructure and thermal analyses, it was found that the vertically aligned micro-rod structures of phenol-formaldehyde resin were formed as a result of the rheological behavior of the thermosetting phenol-formaldehyde resin and the preferential landing phenomenon of the ESD method.

ZIF 재료는 독특한 기체 분리 특성을 포함한 물리적, 화학적 특성 때문에 큰 관심을 받아왔다. 본 연구에서는 α-alumina 지지체 위에 결함 없고 연속적인 ZIF-7 막을 형성하는 새롭고 효율적인 방법이 연구되었다. 지지체 위에 시딩 (seeding)을 하지 않고 직접 ZIF-7 박막을 합성하는데 정전분무법이 처음으로 적용되었다. 이 방법은 전구체 용액을 직접 정 전분무함으로 α-alumina 지지체에 ZIF-7 박막을 형성할 수 있었다. ZIF-7 박막은 XRD, FE-SEM, 단일 기체 투과 장치 등을 이용해 분석하였다.

A new manufacturing process of Fe-Cr-Al powder porous metal was attempted. First, ultra-fine fecralloy powders were produced by using the submerged electric wire explosion process. Evenly distributed colloid (0.05~0.5% powders) was dispersed on PU (Polyurethane) foam through the electrospray process. And then degreasing and sintering processes were conduced. In order to examine the effect of sintering temperature in process, pre-samples were sintered for two hours at temperatures of , , , and , respectively, in atmospheres. A 24-hour TGA (thermo gravimetric analysis) test was conducted at in a 79% +21% to investigate the high temperature oxidation behavior of powder porous metal. The results of the high temperature oxidation tests showed that oxidation resistance increased with increasing sintering temperature (2.57% oxidation weight gain at sintered specimen). The high temperature oxidation mechanism of newly manufactured Fe-Cr-Al powder porous metal was also discussed.

Fe based (FeCSiBPCrMoAl) amorphous powder, which is a composition of iron blast cast slag, were produced by a gas atomization process, and sequently mixed with ductile Cu powder by a mechanical ball milling process. The Fe-based amorphous powders and the Fe-Cu composite powders were compacted by a spark plasma sintering (SPS) process. Densification of the Fe amorphous-Cu composited powders by spark plasma sintering of was occurred through a plastic deformation of the each amorphous powder and Cu phase. The SPS samples milled by AGO-2 under 500 rpm had the best homogeneity of Cu phase and showed the smallest Cu pool size. Micro-Vickers hardness of the as-SPSed specimens was changed with the milling processes.

Fe based (FeCSiBPCrMoAl) amorphous powder, which is a composition of iron blast cast slag, were produced by a gas atomization process, and sequently mixed with ductile Cu powder by a mechanical ball milling process. The experiment results show that the as-prepared Fe amorphous powders less than 90 m in size has a fully amorphous phase and its weight fraction was about 73.7%. The as-atomized amorphous Fe powders had a complete spherical shape with very clean surface. Differential scanning calorimetric results of the as-atomized Fe powders less than 90 m showed that the glass transition, T, onset crystallization, T, and super-cooled liquid range T=T-T were 512, 548 and 36, respectively. Fe amorphous powders were mixed and deformed well with 10 wt.% Cu by using AGO-2 high energy ball mill under 500 rpm.

Ti-45.2at.%Ni-5at.%Cu and Ti-40.2at.%Ni-10atat.%Cu alloy powders were fabricated by gas atomization process. The microstructures, Shape, hardness and phase transformation behaviors of the powders were investigated by means of optical microscopy, scanning electron microscopy, micro-hardness measurement, x-ray diffraction analyses and differential scanning calorimetry. The hardness of the Ti-Ni-XCu alloy powders decreased as Cu-content increased. The x-ray diffraction analyses were carried out for powders without heat treatment, and those that treated at 85 for an hour in a vaccum state( torr) and then quenched into ice water. The intensity of B phase increased with heat treating. The monoclinic B martensite was formed in the Ti-Ni-XCu alloy powders during cooling.