Eslam Hassan and Evgeny A. Trofimov published a review on October 25, 2026, in Powder Technology (impact factor 5.5), systematically assessing the feasibility of solution-derived metal microspheres as feedstock for laser powder bed fusion (LPBF) and directed energy deposition (DED). The article proposes a staged evidence framework that clearly distinguishes "particle formation evidence" from "powder processability evidence," noting that most current solution-based products remain at the stage of single-metal, hollow, porous, or nano-assembled structures and have not yet been validated under real powder processing and laser treatment conditions.
The review covers routes including wet chemical reduction, emulsion-confined growth, spray solution combustion, and secondary conversion. Wet chemical reduction can yield micron-sized spherical metal particles under controlled surfactants, pH, and mixing parameters, but extending this to multi-component microspheres requires that particle formation be coupled synchronously with controlled nucleation, co-reduction behavior, compositional homogeneity, stabilizer removal, and the integrity of drying post-treatment. The core criterion of the article is whether the same powder batch, after recovery, drying, classification, and thermal post-treatment, still maintains particle size distribution, composition, phase state, surface cleanliness, and mechanical integrity—rather than spherical morphology itself. On this basis, the authors define staged validation requirements for claims of powder processability and laser response, covering flowability, spreadability, packing density, and, under actual laser processing, melting behavior, melt pool stability, and defect rates.
For the metal additive manufacturing supply chain, the value of this review lies in shifting the discourse framework of solution methods from "morphology demonstration" to "batch certification." Atomization remains the industrial benchmark; the real opportunity for solution routes lies in the degree of chemical design freedom at the precursor level, but mass balance control, residue management, reproducibility metrics, and laser response feedback constitute conversion barriers from the laboratory to feedstock suppliers.
Value for powder buyers: (1) When evaluating solution-method suppliers, require data on composition, phase state, and oxygen content for the same batch after recovery and classification, rather than morphology photos of as-formed particles; (2) Incorporate flowability, spreadability, and packing density into incoming material acceptance indicators to fill the powder-level evidence gap in most current solution-method reports; (3) For multi-component alloy powders, focus on verifying elemental loss and residues caused by preferential reduction, and require suppliers to provide batch-to-batch reproducibility metrics.
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用于激光粉末技术的溶液法制备金属微球:形成路径、转化壁垒及验证要求
Eslam Hassan与Evgeny A. Trofimov于2026年10月25日在《Powder Technology》(影响因子5.5)发表综述,系统评估溶液衍生金属微球作为激光粉末床熔融(LPBF)与定向能量沉积(DED)原料的可行性。文章提出阶段性证据框架,明确区分"颗粒形成证据"与"粉末可加工性证据",指出当前多数溶液法产物仍停留在单金属、中空、多孔或纳米组装结构阶段,尚未在真实粉末加工与激光处理条件下完成验证。
综述覆盖湿化学还原、乳液限域生长、喷雾溶液燃烧及二次转化等路线。湿化学还原可在受控表面活性剂、pH与混合参数下获得微米级球形金属颗粒,但扩展至多元组分微球时,颗粒形成必须与受控成核、共还原行为、成分均匀性、稳定剂去除及干燥后处理完整性同步耦合。文章的核心判据是同一粉末批次经回收、干燥、分级和热后处理后,是否仍保持粒度分布、成分、相态、表面洁净度与机械完整性——而非球形形貌本身。作者据此定义了粉末可加工性与激光响应声明的分阶段验证要求,涵盖流动性、铺展性、堆积密度及实际激光加工下的熔化行为、熔池稳定性与缺陷率。
对金属增材制造产业链而言,这篇综述的价值在于把溶液法从"形貌演示"推向"批次认证"的话语框架。雾化仍是工业基准,溶液路线的真正空间在于前驱体水平的化学设计自由度,但质量平衡控制、残留物管理、可重复性指标与激光响应反馈构成从实验室到原料供应商的转化壁垒。
对粉末采购商的价值:① 评估溶液法供应商时,要求其提供同一批次经回收与分级后的成分、相态及含氧量数据,而非形成态颗粒的形貌照片;② 将流动性、铺展性与堆积密度纳入来料验收指标,弥补当前多数溶液法报道缺失的粉末级证据;③ 对多元组分合金粉末,重点核查优先还原导致的元素损失与残留物,并要求供应商给出批次间可重复性指标。