Powder Development and Characterization for Additive Manufacturing of FeMnAlC Alloy Steel

FeMnAl high alloy steel has been evaluated for its potential weight reduction benefits as a direct replacement for mild steel, showing near-equivalent performance with a 12-18% reduction in density. Direct energy deposition (DED) can be used for production and repair of high alloy steel components using a powder feedstock. Gas atomized steel powders can be produced at high yields in the 60-125 µm size range using existing metallurgical furnace technology. Transferred-arc plasma melting in a cold hearth under vacuum-evacuated and inert-gas-purged conditions has been shown to be effective at melting and mixing steel without introducing contaminants. Scrap or virgin feedstock can be used to produce the steel which is subsequently atomized by high pressure argon.