Particle morphology control of metal powder with various experimental conditions using ball milling

The morphology evolution of copper powder was studied under various ball-milling experimental conditions, such as low and high rotation speeds and a ball diameter of 1 mm and 10 mm. A scanning electron microscope and X-ray diffractometer were used to analyze the copper powder particle size, morphology, structure, and crystallite size. The effect of ball size on copper powder particle morphology in dry-type milling was studied using a planetary ball mill. Spherical copper powders were obtained by ball milling at a high rotation speed and with a ball diameter of 1 mm. The experimental results suggest that the particle size and morphology can be controlled by changing the milling conditions during the ball milling. Ball motion was simulated by using a three-dimensional discrete-element model to obtain the force, energy, and power of the ball motion in the ball mill for two different ball sizes and low and high rotation speeds.