Characterization of the ultrafine and fine particles formed during laser cladding with the Inconel 718 metal powder by means of X-ray spectroscopic techniques

Additive manufacturing is a rapidly growing industrial technology. Still, there is a lack of knowledge regarding the fine particle emission and new particle formation during the processes and their consequences on the performance of the operation and the operator's health as well. Therefore, we studied the properties of the emitted particles during the 3D printing process using the Inconel 718 (Ni-based) superalloy. The number and the mass concentrations were measured with a Scanning Mobility Particle Counter and Sizer. Size-fractionated samples were collected by a cascade impactor, and the elemental composition of the particles was determined by total-reflection X-ray fluorescence analysis, Scanning Electron Microscopy, Energy Dispersive Spectroscopy, and microscopic X-ray fluorescence analysis in the different size fractions. The oxidation states of the metals (Cr, Mn, Fe, Ni) in the samples were determined with the X-ray absorption near-edge structure (XANES) method. Most of the particles were found in the ultrafine region with a size below 100 nm, and the mass size distribution had the maximum at 85 nm. In the original powder, Ni was dominating with appr. 52 wt%, and the proportion of Cr was around 20 wt%, and Mn was below 1 wt%. In the released particles, the Ni content decreased to appr. 26 wt%, the Cr content increased to appr. 47 wt% and Mn increased to around 10 wt% for particles with a size between 0.07 and 10 μm. According to the XANES results, Cr, Mn and Fe were found to be oxidized significantly, whereas Ni remained in the metallic form in the total emitted aerosol containing mostly ultrafine particles. The enrichment and oxidation of metals were correlated with each other. [Display omitted] •Aerosol particle formation was studied during additive manufacturing technology.•Most newly formed particles were found in the ultrafine region (below 100 nm).•X-ray methods used for chemical and morphological characterization of particles.•Cr and Mn enriched in the released particles compared to the original Ni-alloy.•Oxidation state of metals was in correlation with enrichment in ultrafine particles.