Microstructures and Properties of Spherical W-25%Re Alloy Powders Produced by Wire Electrical Explosion Method AITranslate

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Basic Information:

DOI：10.13373/j.cnki.cjrm.XY24020032

Chinese Library Classification Number:TG456.3

Citation Information:

Wire electric explosion method involves introducing a large pulse current into metal wire to create an electric explosion process，resulting in the production of metal powders. This method is commonly used to produce nano-scale spherical powders and offers advantages such as small size，low energy consumption，and high performance of the resulting spherical metal powders. This study utilized W-25%Re （mass fraction，the same below） alloy wire with a diameter of 0.3 mm as the raw material and employed the wire electric explosion method to produce micron-sized spherical W-25%Re alloy powders. The findings offered valuable insights for the efficient production of high-quality micron-sized spherical refractory alloy powder for selective laser melting （SLM） applications. The spherical W-25%Re alloy powder prepared in the experiment was categorized into five kinds particle size ranges：<5，5~35，35~60，60~165 and >165 μm. These particle sizes were chosen for analysis to investigate the microstructures and properties of spherical W-25%Re alloy powders. The powders morphology，laser particle size，flowability，apparent density，tap density，oxygen content and phase were measured using scanning electron microscope，laser particle size analyzer，flowability and apparent density tester，multi-functional powder physical property tester，oxygen and nitrogen analyzer，and X-ray diffraction （XRD）. The particle size 5~35，35~60，60~165 and >165 μm exhibited excellent sphericity，a high spheroidization rate. The particle size <5 μm featured small particle size and large specific surface area，leading to strong van der Waals forces among particles and potential agglomeration. Additionally，the particle size 5~35，35~60，60~165 and >165 μm demonstrated nearly 100% spheroidization rate. Except for the powder with particle size <5 μm，which had a wide distribution range due to severe agglomeration，the particle size distribution of the other four powders were narrow and relatively concentrated. The powders with a particle size of <5 μm were smaller and more active. The oxygen content of the powder raw materials was significantly increased，while powders with a particle size of >165 μm might introduce impurities due to waste residues，leading to a relatively high oxygen content. Furthermore，powders in other particle size ranges of oxygen content similar to that of W-25%Re alloy wire，aligning with the principle that finer powders had higher activity and oxygen content. Re content in the powder varied depending on the particle size. For particles with particle size <5 μm，Re content was 28.03%，slightly higher than that of the raw material wire. In contrast，Re content in powders of other particle size segments closely matched that of the raw material. This discrepancy might be due to impurity oxygen combining with rhenium at high temperatures during wire explosion，forming volatile oxides that adhere to powder particles upon cooling. The larger specific surface area of particles with particle size <5 μm led to more oxide deposition，resulting in a slightly higher Re content compare to the raw wire material. Except for powders with particle size <5 μm，which tended to agglomerate and had poor fluidity，and powders with particle size >165 μm，which were often discarded as waste，the flowability of powders with particle size of 5~35，35~60 and 60~165 μm were 6.95，5.09 and 5.34 s·（50 g）⁻¹，respectively，indicating good flowability，and their apparent densities were 12.00，11.42 and 11.57 g·cm⁻³，respectively，while tap densities were 13.2，12.3 and 12.6 g·cm⁻³. The minimal variation in bulk and tapped densities within this particle size range suggested that the prepared powder exhibited good sphericity and density. For particles with particle size <5 μm，the phases were the tetragonal crystal system W_0.4Re_0.6 phase，cubic crystal system W_0.8Re_0.2 and W₃Re phase. For particles with particle size of 5~35，35~60，60~165 and > 165 μm exhibited cubic crystal system W₁₃Re₇ phase. When particle size increased from 8.945 to 217.98 μm，the solidification structure on the surface of the powder particles gradually changed from a lack of obvious crystalline state and cellular crystals to dendrites. The relationship between the particle size （d） and the secondary dendrite arm spacing （λ） was expressed as：λ=0.727+5.59×10⁻³d. As the particle size increased，the secondary dendrite arm spacing also increased，demonstrating a linear correlation between the two. The interior of spherical W-25%Re alloy powders exhibited high density and had no obvious defects. As the particle size increased，the internal grain structure changed from cellular crystals to dendrites. The micron-sized spherical W-25%Re alloy powders，producing through wire electric explosion，demonstrated excellent overall properties. The particles with particle size of 5~35 μm possessed high sphericity，uniform particle size distribution，low oxygen content，good fluidity，high bulk density and tap density. These characteristics made it well-suited for meeting the powder performance requirements of SLM technology.