Providing New Opportunities for High-Performance Metal Powder Applications: Research on VMP’s Rotating Electrode Process for GH3536—Effect of Rotational Speed

Panda3dp.com guide:GH3536 is a solid-solution strengthened nickel-based superalloy known for its exceptional corrosion resistance and high-temperature strength, making it suitable for prolonged use below 900°C. It is widely used in manufacturing hot-end components for aero engines. In response to the stringent requirements of the aerospace industry for lightweight and high-strength materials, fabricating GH3536 alloy components through laser additive manufacturing has become a prominent research focus.

VMP（威拉里）, a renowned domestic supplier of 3D-printed metal powders, specializes in developing and producing high-end materials such as titanium alloys and superalloys. With years of experience in metal powder production and new material development, VMP is among the few manufacturers in China with a fully independent manufacturing capability for 3D printing materials.

According to Panda3dp.com, VMP's R&D team, driven by market demand, employs the PREP process to produce additive manufacturing-specific GH3536 alloy powder. Their research reveals that powders produced at different rotational speeds have particle sizes concentrated within the 15–70 µm range. Increasing the rotational speed leads to a gradual reduction in particle size (Figure 1).

Figure 1: Powder Particle Size Distribution at Various Rotational Speeds

As shown in Figure 1, the rotational speed of the bar material influences the average particle size of the powder. The reduction in liquid film thickness and the increase in centrifugal force acting on the liquid line at high rotational speeds result in an elongated liquid line. This leads to a higher number of smaller droplets formed during primary fragmentation, as well as more thorough secondary fragmentation, thereby reducing particle size. However, beyond a certain rotational speed, further reduction in average particle size becomes challenging due to the increasing likelihood of adjacent liquid droplets interacting and recoalescing.

Table 1: Comprehensive Physical Properties of GH3536 Powders Produced at Different Rotational Speeds

Table 1 illustrates that as rotational speed increases, the loose bulk density of the powders gradually rises, and their flowability improves. This is attributed to the enhanced centrifugal force acting on the liquid film at the bar's end, resulting in more uniform particle size distribution and grading, ultimately improving the overall physical properties of the powders.

Figure 2: Influence of Rotational Speed on Powder Morphology

The spherical powders of GH3536 produced using VMP's optimized key powder production parameters demonstrate significant advantages in flowability, bulk density, particle size distribution, and sphericity compared to existing literature (Figure 2). Third-party verification confirms that powders within the 15–53 µm range have a sphericity exceeding 95%, a hollow powder rate below 0.05%, no high-density inclusions, a Hall flow rate of 11.6s/50g, a loose bulk density of 5.15g/cm³, and a tapped density of 5.45g/cm³, offering new possibilities for high-performance metal powder applications.

Currently, VMP’s production facility boasts 20 powder production units, including 9 EIGA furnaces and 10 VIGA furnaces. Notably, the company is equipped with a 500kg large-scale melting atomization furnace capable of a single batch feed of 500kg, producing up to 1 ton of qualified powder per day, a capability that stands out domestically.

Panda3dp.com also reported that VMP’s second-phase production line is expected to reach a powder production capacity of 1,500 tons, with titanium alloy powder lines increasing from 6 to 9, significantly enhancing titanium powder output. Additionally, all existing VIGA equipment will be upgraded to 500kg large-capacity atomization furnaces, further expanding the company’s powder production capacity.

Apart from its advanced production processes, VMP has also made significant strides in new material development. The recently launched A60X high-strength aluminum alloy maintains tensile strength ≥600MPa, yield strength ≥550MPa, and elongation ≥9% in the heat-treated state. The material shows excellent repeatability in printing trials, a wide processing parameter window, and stable printability. Moreover, A60X exhibits good high-temperature performance, retaining tensile strength ≥140MPa at 250°C.

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VMP has breakthroughs in high-temperature alloys. The company’s newly developed IN738 superalloy powder, designed for use in 900–950°C environments, outperforms traditional alloys such as GH4169 and GH3536, offering significant advantages in applications for engines and other high-temperature components.