Mechanical Alloying Process Design by Using DEM Simulation and Experimental Validation

Mechanical alloying plays a crucial role in controlling and enhancing the characteristics of powder materials which in turn influence the quality and performance of thermal spray coatings. In this study, the optimal milling parameters for mechanical alloying were determined, specifically a rotational speed of 60 rpm, a milling period of 6 hours, and wet milling conditions. These settings led to the best preparation of feedstock powder, resulting in a minimal particle size of 17.5 µm and a narrow particle size dispersion. The observed extensive cataracting and impact zones at this rotational speed of 60 rpm corresponded to 65 of the % critical speed, indicating enhanced milling efficiency. Additionally, DEM modeling demonstrated good agreement with experimental findings, indicating enhanced milling efficiency. Additionally, DEM modeling demonstrated good agreement with experimental findings, highlighting that this rotational speed induced a cataracting regime characterized by a broad zone of impacted particles, yielding the highest impact velocity of 1.79 m/s and a ball indenter force interaction of 1.19 N.