Effect of the particle size distribution on physical properties, composition, and quality of gas atomized Astroloy powders for HIP application

Hot Isostatic Pressing (HIP) is a well-known technique that lately is gaining more interest because of its growing involvement in the Additive and Near-Net Shape manufacturing fields. When HIP is used for near-net-shape manufacturing, the raw gas atomized powders assume the uttermost importance, and special attention should be given to their quality and characteristics. Based on this statement, the powder should be sieved directly after production to select only those that best suit the HIP process. Typically, a broad Particle Size Distribution is indicated for HIP purposes and looks economically advisable because it leads to a higher yield. Despite this, if the PSD is not strictly controlled, particles with high Oxygen content or chemical inhomogeneity could enter the production chain, leading to compacted components with insufficient mechanical properties. In this paper, Nickel-based superalloy Astroloy particles were assessed in depth both at their surface and in the core, dividing them into sub-batches via mechanical sieving. This procedure evidenced which contribution was brought to the final raw material by each sub-batch. Furthermore, physical properties such as flowability and tap density were studied as a function of the PSD. Next, a complete morphological assessment was conducted to understand the possible defects of each sub-batch better. Similarly, every particle group was chemically studied to determine the Oxygen, Carbon, Nitrogen, and Hydrogen content of each sub-batch. Micro and nano indentations combined with EBSD were used to understand how the particle size may affect the mechanical properties of the powders during the Hot Isostatic pressing. Furthermore, EDS and XRD analysis were used to thoroughly understand how Ti segregation starts forming and what effects are likely to develop. Based on these investigations, it was possible to rationally identify the upper and lower boundary for particle PSD without excessively limiting the overall process yield.