Experimental Investigation of Electrical Parameter Effects in Wire Arc Atomization of 316L Stainless Steel Powders for Additive Manufacturing

Conventional industrial‐scale production of metal powders generally occurs in large plants, where each batch sizes several hundred kilograms of powder. However, these production methods are economically impractical for manufacturers with lower demands, such as those involved in prototyping and developing new alloys for additive manufacturing. This study investigates wire arc atomizing as a viable alternative for producing metal powders that are specifically tailored to precise requirements and manufactured in a batch size of one. The wire melting process is controlled by modulating the electrical current, using pulsed and unpulsed DC. Arc power varies across a wide range to assess its impact on particle size distribution. Furthermore, the produced metal powders undergo comprehensive characterization and evaluation to determine their suitability for additive manufacturing, ensuring they meet specific application requirements.