SUSTAINABLE PRODUCTION OF ALUMINUM POWDER FOR ADDITIVE MANUFACTURING: A COMPREHENSIVE INVESTIGATION OF ALUMINUM POWDER CHARACTERISTICS FROM WATER ATOMIZATION TECHNIQUES
DOI:
https://doi.org/10.4314/njt.2026.4307Keywords:
metal powders, sustainable manufacturing, metal powders, cleaner manufacturing, recycling, environmental sustainabilityAbstract
In this paper, the qualities of aluminum powder made from industrial aluminum scrap through water atomization for use in Additive Manufacturing were examined. This investigation aims at determining what factors the water atomization process have on the quality of the powder, and if it can be utilized as a sustainable method of manufacturing. Aluminum powder was created under controlled conditions by altering some of the primary aspects of the process; specifically, water pressure and the molten metal's temperature. We used two types of spectroscopic analysis, Energy Dispersive X-ray Spectroscopy (EDX), and X-ray Fluorescence (XRF) to measure the chemical makeup of the aluminum powder, as well as particle size distribution, particle morphology, and compatibility with additive manufacturing processes. The results indicate that water atomization creates aluminum powder with particles that are generally in the size range of 20–100 μm. The EDX and XRF showed that the aluminum powder contained approximately 80.63% aluminum, and there were variances in elemental composition and relatively large amounts of oxygen content that averaged approximately 43.5%. Small amounts of other minor elements, including silicon, copper, and iron were also observed, which may be due to the alloying elements within the scrap material. Additionally, the powders demonstrated irregular shapes to their particles, which is representative of the inherent properties of the water-atomized powders produced from recycled aluminum feedstocks. Overall, this research has shown the viability of producing powder from aluminum scrap as an alternate source of raw material for powder production, and will help to increase sustainability of the supply chain for Additive Manufacturing, by reducing dependence on virgin material, decreasing energy requirements and minimizing environmental impacts of traditional powder production methods.
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