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<p>This study investigates the production of high-purity spherical 410 NiMo stainless steel powder using an advanced wire plasma atomization process. The method employs a transferred arc plasma torch operating in reverse polarity with argon as the plasma-forming gas. The influence of gas consumption on the powder’s particle size distribution was experimentally analyzed. Results indicate that an argon flow rate of 150&#xa0;L/min optimizes the yield of the 50–150&#xa0;μm fraction, reaching 54 wt%, which is critical for directed energy deposition (DED) - including laser, plasma and electron beam additive manufacturing. The produced powders exhibit high sphericity (≈ 0.9), minimal internal porosity, and a low content of satellites and irregularly shaped particles (less than 1 vol%). The experimental results reveal a notable reduction in gas impurities during the process, where the nitrogen content decreased by a factor of four (from 0.0181 to 0.0045 wt%) and the oxygen content dropped by ≈ 15% (from 0.0149 to 0.0127 wt%) in the resulting powder compared to the initial wire. The resulting powder demonstrates improved flowability and bulk density characteristics relative to conventional gas and water-atomized powders, while exhibiting properties highly comparable to those produced via the plasma rotating electrode process (PREP). These characteristics indicate the strong potential of the developed 410 NiMo powder for laser, plasma, and electron-beam additive manufacturing. This potential was preliminarily validated during the plasma metal deposition (PMD) process, where the powder demonstrated stable feeding and the resulting deposited metal exhibited a uniform macrostructure without visible defects.</p>

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Production of high-purity spherical 410 NiMo stainless steel powder via plasma atomization for additive manufacturing

  • 期刊论文

  • 发表日期：

    2026年6月26日

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  • Volodymyr Korzhyk,
  • Dmytro Strohonov,
  • Oleksii Tereshchenko,
  • Yuriy Torba,
  • Sergii Chygileichyk,
  • Ruslan Kulykovskyi,
  • Oleksandr Chechet

摘要

This study investigates the production of high-purity spherical 410 NiMo stainless steel powder using an advanced wire plasma atomization process. The method employs a transferred arc plasma torch operating in reverse polarity with argon as the plasma-forming gas. The influence of gas consumption on the powder’s particle size distribution was experimentally analyzed. Results indicate that an argon flow rate of 150 L/min optimizes the yield of the 50–150 μm fraction, reaching 54 wt%, which is critical for directed energy deposition (DED) - including laser, plasma and electron beam additive manufacturing. The produced powders exhibit high sphericity (≈ 0.9), minimal internal porosity, and a low content of satellites and irregularly shaped particles (less than 1 vol%). The experimental results reveal a notable reduction in gas impurities during the process, where the nitrogen content decreased by a factor of four (from 0.0181 to 0.0045 wt%) and the oxygen content dropped by ≈ 15% (from 0.0149 to 0.0127 wt%) in the resulting powder compared to the initial wire. The resulting powder demonstrates improved flowability and bulk density characteristics relative to conventional gas and water-atomized powders, while exhibiting properties highly comparable to those produced via the plasma rotating electrode process (PREP). These characteristics indicate the strong potential of the developed 410 NiMo powder for laser, plasma, and electron-beam additive manufacturing. This potential was preliminarily validated during the plasma metal deposition (PMD) process, where the powder demonstrated stable feeding and the resulting deposited metal exhibited a uniform macrostructure without visible defects.