Gas atomization of AA2017 aluminum alloy: Effect of process parameters in the physical properties of powders for additive manufacturing

Close-coupled gas atomization (CCGA) uses pressurized gas jets to atomize molten metals, producing powders suitable for additive manufacturing (AM). Optimization of processing parameters is crucial to achieve powders with good fluidity and high apparent density for laser powder bed fusion (L-PBF) and increase production yield. This study evaluated the influence of melt feed nozzle diameter, superheating temperature, and atomization pressure on AA2017 aluminum alloy powders' physical properties. Parameters variation poorly affected the median particle diameter (), while significantly altering the particle size distribution curves width (IDR = -). Suitable powders for AM/L-PBF were produced using a specific set of parameters (= 1.5 mm; = 150 ºC; = 20 Bar), presenting appropriate fluidity and apparent density due to an optimal granulometric distribution and morphological characteristics. Mathematical analysis showed a good correlation between experimental and calculated mean particle size, suggesting an equation to predict percentile based on previous correlations.