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A comparative study of laser direct metal deposition characteristics using gas and plasma-atomized Ti-6Al-4V powders

This paper described cross disciplinary research (Manufacturing Engineering - Material Science), that was supported in kind by the deposition industry (e.g. powder supplier LPW Technology Ltd, phil.carroll@lpwtechnology.com). The work investigated microstructure and porosity in DMD parts built using Gas Atomised and PREP powders. The work reliably achieved this where others had failed before by using high resolution volumetric analysis (microCT), XRD and SEM analyses together. The results clarified porosity formation mechanisms and the paper was also the first to draw attention to the importance of variable nucleation density due to powder flow for final microstructure formation.