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<p>In order to make full use of the advantages of additive manufacturing for the preparation of ceramic–metal matrix composites and to meet the demand for composite powders, this paper adopts the gas–solid two-phase flow atomization method to prepare Al<sub>2</sub>O<sub>3</sub>/FeNi composite powders. According to the particle size requirements of composite powders for additive manufacturing, the composite powders are sieved, and the morphology, particle size distribution, surface solidification microstructure, phase composition, and irregular powders are characterized. The results show that the composite powder has a high degree of sphericity, and that the Al<sub>2</sub>O<sub>3</sub> particles are diffusely distributed in the surface layer and the interior of the powder. The microstructure evolution of the powder surface has been observed, which is decomposed from the planar interface into cellular, dendritic, and equiaxed structures. In addition, the formation mechanism of three types of satellite powder and two types of hollow powder has been analyzed in detail. Finally, it has been found that the powder matrix consists of γ(Fe,Ni) solid solution with face-centered cubic structure under the condition of high cooling velocity, which leads to the shift of the strongest XRD peak to higher diffraction angles due to the grain refinement.</p>

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Characterization of Al2O3/FeNi Composite Powders Prepared by Gas–Solid Atomization Method for Additive Manufacturing

  • 期刊论文

  • 发表日期：

    2025年8月11日

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  • Jinli Xiang,
  • Guixiang Zhang,
  • Yandan Xia,
  • Linzhi Jiang,
  • Haozhe Zhang,
  • Kai Zhao,
  • Guoyong Zhao,
  • Haiyun Zhang

摘要

In order to make full use of the advantages of additive manufacturing for the preparation of ceramic–metal matrix composites and to meet the demand for composite powders, this paper adopts the gas–solid two-phase flow atomization method to prepare Al2O3/FeNi composite powders. According to the particle size requirements of composite powders for additive manufacturing, the composite powders are sieved, and the morphology, particle size distribution, surface solidification microstructure, phase composition, and irregular powders are characterized. The results show that the composite powder has a high degree of sphericity, and that the Al2O3 particles are diffusely distributed in the surface layer and the interior of the powder. The microstructure evolution of the powder surface has been observed, which is decomposed from the planar interface into cellular, dendritic, and equiaxed structures. In addition, the formation mechanism of three types of satellite powder and two types of hollow powder has been analyzed in detail. Finally, it has been found that the powder matrix consists of γ(Fe,Ni) solid solution with face-centered cubic structure under the condition of high cooling velocity, which leads to the shift of the strongest XRD peak to higher diffraction angles due to the grain refinement.