Particle morphology control of metal powder with various experimental conditions using ball milling

The morphology evolution of copper powder was studied under various ball-milling experimental conditions, such as low and high rotation speeds and a ball diameter of 1 mm and 10 mm. A scanning electron microscope and X-ray diffractometer were used to analyze the copper powder particle size, morphology, structure, and crystallite size. The effect of ball size on copper powder particle morphology in dry-type milling was studied using a planetary ball mill. Spherical copper powders were obtained by ball milling at a high rotation speed and with a ball diameter of 1 mm. The experimental results suggest that the particle size and morphology can be controlled by changing the milling conditions during the ball milling. Ball motion was simulated by using a three-dimensional discrete-element model to obtain the force, energy, and power of the ball motion in the ball mill for two different ball sizes and low and high rotation speeds. [Display omitted] •Milling media and rotation speed effects in particle morphology were explored experimentally.•Impact force and contact number in particle morphology evolution were investigated.•Force and cumulative energy of balls in ball milling are investigated via the DEM simulation.•The reason for the spherical particle morphology evolution is the contact number.