2025 AIChE Annual Meeting

(292f) Surface Modification of Additive Manufacturing Feedstocks

Authors

Arrelaine A. Dameron, Forge Nano, Inc.
Christopher Gump, ALD NanoSolutions, Inc.
Markus D. Groner, ALD NanoSolutions, Inc.
Casey Christopher, Forge Nano
Dane Lindblad, Forge Nano
Brandon Woo, Forge Nano
Joseph Gauspohl, Forge Nano
Anthony Manerbino, Elementum 3D
Jeremy Iten, Elementum 3D
Additive Manufacturing (AM), also called 3D printing, constructs objects from a digital model, typically by depositing and solidifying material layer by layer. AM processes that utilize powder feedstocks include laser powder bed fusion and binder jetting. AM can manufacture objects with intricate internal structures and/or small features that cannot be easily or economically fabricated by top-down machining methods or when these machining tools are not available. However, the number of alloys that can be printed successfully with superior mechanical properties by AM is limited. Possible reasons include 1) the crystal structure/internal stresses of the as-printed part leads to adverse mechanical properties, 2) the feedstock powders do not flow well and are difficult to print uniformly leading to part defects, or 3) high reflectivity of the feedstock preventing effective absorption of input energy, 4) the powder is sensitive to ambient air and has a limited shelf life or powder degradation leads to chemical inclusions and defects. These material deficiencies can be mitigated by nanoscale surface coatings that are chemically precise and uniformly distributed. We demonstrate atomic layer deposition (ALD) Al2O3, SiO2 and Y2O3 coatings on AlSi10Mg, Ti64, and SiC powders at gram and kg scale. ICP, LECO, and STEM imaging and elemental mapping demonstrated successful surface modification. These coatings increased feedstock oxidation resistance by acting as a moisture and oxygen barriers, and increased powder flowability, demonstrated by a reduction in Hall Flow time. 3D printed cubes and bars from each material were tested ‘as printed’ and after hot isostatic pressing. Parts using the ALD-coated material had the highest density, yield stress, and UTS, while also having the lowest surface roughness.