A new powder production method has been developed to speed up the search for novel alloys for additive manufacturing. The technique involves an ultrasonically agitated cold crucible installed at the top of a 20 kHz ultrasonic sonotrode. The material is melted with an electric arc and undergoes pulverization with standing wave vibrations. Several different alloys in various forms, including noble and metallic glass alloys, were chosen to test the process. The atomized particles showed exceptional sphericity, while powder output suitable for additive manufacturing reached up to 60%. The AMZ4 metallic glass powder remained amorphous below the 50 μm fraction, while tungsten addition led to crystallization in each fraction. Minor contamination and high Mn and Zn evaporation, especially in the finest particles, was observed in atomized powders. The innovative ultrasonic atomization method appears as a promising tool for material scientists to develop powders with tailored chemical composition, size and structure.

Synthesis and characterization of composite shear thickening fluids (STFs) containing carbon nanofillers are presented. Shear thickening fluids have attracted particular scientific and technological interest due to their unique ability to abruptly increase viscosity in the case of a sudden impact. The fluids have been developed as a potential component of products with high energy absorbing efficiency. This study reports on the rheological behavior, stability, and microstructure of the STFs modified with the following carbon nanofillers: multi-walled carbon nanotubes, reduced graphene oxide, graphene oxide, and carbon black. In the current experiment, the basic STF was made as a suspension of silica particles with a diameter of 500 nm in polypropylene glycol and with a molar mass of 2000 g/mol. The STF was modified with carbon nanofillers in the following proportions: 0.05, 0.15, and 0.25 vol.%. The addition of the carbon nanofillers modified the rheological behavior and impact absorption ability; for the STF containing 0.25 vol.% of carbon nanotubes, an increase of force absorption up to 12% was observed.

Selective Laser Melting was successfully used as a fabrication method to produce Ni-Mn-Ga and Ni-Mn-Ga-Fe ferromagnetic shape memory alloys. The starting material in a powder form with an average particle size of about 17.6 µm was produced by milling of as melt-spun ribbons. The microstructure, phase composition, and martensitic transformation behavior of both powder precursors and laser melted alloys were investigated by several methods, including high energy X-ray diffraction, electron microscopy, and vibrating sample magnetometry. The as laser melted materials are chemically homogenous and show a typical layered microstructure. Both alloy compositions have a duplex structure consisting either of austenite and 10M martensite (Ni-Mn-Ga) or a mixture of 14M and NM martensitic phases (Ni-Mn-Ga-Fe), contrary to the as milled powder precursors showing fcc structure in both cases. The forward martensitic transformation takes place at 336 and 325 K for Ni-Mn-Ga and Ni-Mn-Ga-Fe, respectively, while the magnetic response is much stronger for Ni-Mn-Ga than for the quaternary alloy. The results show that Selective Laser Melting allows for producing of good quality, homogenous materials. However, their microstructural features and consequently shape memory behavior should be tailored by additional heat treatment.