Formation of spherical alloy microparticles in a porous salt medium

Hayk H. Nersisyan, Suk Cheol Kwon, Vladislav E. Ri, Wan Bae Kim, Woo Seok Choi, Jong Hyeon Lee

Research output: Contribution to journalArticlepeer-review


This study describes the development of a one-pot strategy to produce spherical alloy microparticles for advanced near-net-shape manufacturing processes, including additive manufacturing and powder injection molding. The AlSi12 eutectic alloy (ca. 12 wt% Si) system was chosen as the model with which the main experiments were carried out. The proposed process synergistically integrates a few common, low-cost processing techniques including the mixing of Al micrometer size particles with silicon and sodium chloride, heat-treating the mixture at temperatures of 650–810 °C, and the dissolution of salt in water to produce spherical AlSi12 alloy particles without the need to rely on costly melting and atomizing techniques. This new process can use laow-cost source Al and Si powders as the raw materials to produce 10–200 μm-sized spherical particles of AlSi12. The Ansys-CFX computational fluid dynamics software was used to analyze the flow behavior of AlSi12 liquid droplets and particle size refinement in the narrow voids of the sample.

Original languageEnglish
Pages (from-to)189-196
Number of pages8
JournalJournal of Materials Science and Technology
Publication statusPublished - 2020 Apr 15
Externally publishedYes


  • AlSi12 alloy
  • Morphology evaluation
  • Particle distribution
  • Simulation
  • Solid-liquid transition
  • Spheroidization

ASJC Scopus subject areas

  • Ceramics and Composites
  • Mechanics of Materials
  • Mechanical Engineering
  • Polymers and Plastics
  • Metals and Alloys
  • Materials Chemistry


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