Effect of ultrasonic atomization parameters on AlSi12 aluminum powder characteristics for additive manufacturing

The adoption of additive manufacturing (AM) has driven extensive research into metal feedstocks, uncovering strong links between powder quality and the performance of printed parts. Poor powder characteristics, inadequate flowability or inconsistent packing, can significantly degrade the mechanical performance of the final 3D-printed components. This study investigates the effects of arc manipulator angle, electrical current, and vibration amplitude on AlSi12 powder quality via ultrasonic atomization (UA). Parameter adjustments significantly influenced particle size distribution, with span variations up to 37.5%. Optimal rheological properties were achieved by increasing the vibration amplitude (from 75 to 80%), decreasing the arc angle (from 5° to -5°), and reducing the current (from 150 A to 140 A). A modified AM suitability factor (AMS) was developed, incorporating logarithmic transformation and custom weighting to mitigate high-uncertainty parameter effects. Results revealed a non-linear relationship between powder suitability and arc angle, with a sharp worsening above 0°. Electrical current had the greatest impact on powder quality, followed by arc angle and vibration amplitude. Benchmarking showed that UA powder achieved suitability factors 21% higher than commercial powder, with improved sphericity compared to the irregular, fused particles of commercial alternatives. These findings underscore the potential of UA to enhance AM part reliability.