Preparation of IC21 Spherical Powders by PREP Process

The IC21 spherical powders with main content of Ni3Al were successfully manufactured by the high speed plasma rotating electrode process (HS-PREP). The powders particle size distribution fitted the mixed spraying model well. The chemical contents changes after melting were detected. The microstructure of the IC21 powders was formed by cellular crystal on the surface and dendrite inside, which was a typical PREP powder. The morphologies and properties of the irregular powders were also analyzed which indicated that the composition segregation and oxides inclusion of the electrode were the main reason for the formation. However, its proportion was less than 0.5%, which would not affect the additive manufacturing. The fundamental powder particle size distribution data for different rotating speeds was measured. The morphology and properties result show that the PREP could support qualified IC21 spherical powders with significant powder yields.