Enhancing Flow Behavior and Mechanical Properties in Powder-Based Additive Manufacturing: The Impact of Particle Size Variations and Nanoparticle Coating on 316L Stainless Steel Powder

This study investigates the crucial role of powder flowability in powder-bed-based additive manufacturing (AM), with a focus on the influence of particle size variations and nanoparticle coatings. In laser powder bed fusion (LPBF) processes, maintaining optimal flow is essential for ensuring high-quality parts and a stable process. The impact of fumed silica (SiO2) nanoparticle coatings on the initial flow behavior of standard gas-atomized 316L powder, as well as powders with modified size distributions (0-45 μm, 15-63 μm, 0-63 μm), was investigated. The results indicate that nanoparticle coatings improve flowability and bulk density, demonstrating economic potential for LPBF processing of coated powders. The powders that have been coated display a higher relative density and better mechanical properties, such as improved tensile strength, when compared to their uncoated counterparts.