Comprehensive analysis of ultrasonically atomized 316L stainless steel powder using adjusted additive manufacturing suitability factor

This study focuses on the 316L stainless steel powder produced by using an innovative ultrasonic atomization (UA) method. The production process was optimized at electrical currents with 120 A and vibration amplitude with 80% proving the most effective for maximizing productivity. The study extensively evaluated particle size and shape, bulk and tapped densities, Hausner's ratio, and Carr index, finding the UA steel powder to possess high sphericity, minimal satellite particles, and excellent flowability, qualities crucial for additive manufacturing (AM). A new approach for calculating the additive manufacturing suitability factor was developed, incorporating custom weighting factors for rheological parameters to reduce the influence of parameters with high uncertainty or statistical insignificance, thus improving accuracy. When compared using this method, the UA powder demonstrated superiority over its commercial counterparts by approximately 1% and 10%, underscoring its promise for AM applications.