A Predictive Strength Model with Experimental Characterization for Gas-Atomized Aluminum Powder

For certain solid-state additively manufactured processes, more attention is being given to the initial mechanical properties of feedstock powder as they play a role in determining the final properties of the deposit. To quantify the mechanical properties of the powder, and therefore predict the performance of the consolidated material, a predictive strength model is being developed to consider strengthening contributions from solid solution, precipitation, dispersion and grain size. Parameters for these models are calculated using thermodynamic and kinetic software, namely Thermo-Calc and TC-PRISMA. The results of the additive strength model are experimentally verified for several aluminum alloys including Al 2024, 5056, 6061, and 7075. Microstructural characterization and quantification are performed utilizing techniques such as scanning and transmission electron microscopy, x-ray diffraction, and differential scanning calorimetry.