Pilot design of experiment study: effect of stirring duration and guest particle loading on electrostatic adsorption of Ti-6Al-4V composite powder formation

Abstract In recent years, materials science and engineering have increasingly focused on advanced composite powders. This study examines the preparation of micro–micro Ti-6Al-4V composite powders by electrostatic adsorption (EA). The necessity of this research lies in the demand for optimizing the Ti-6Al-4V composite powder formation process window for high-performance applications across industries. Achieving optimal EA parameters is crucial for enhancing the quality and efficiency of the powder formation process. In this study, the effect of stirring duration and guest particle loading on the EA process is investigated. The stirring time (1 to 25 min) and guest particle loading (10 to 60%) of the solution are varied to determine the ideal conditions for high adsorption efficiency. It was found that shorter stirring durations (1 min) and a lower guest particle load (10%) have a significant effect on adsorption efficiency. The results were analyzed using the DOE approach to guide future optimization of the process window. The study fills a research gap by utilizing the DOE approach to investigate stirring duration and guest particle loading, providing insights for optimizing the EA process for micro–micro Ti-6Al-4V composite powder. This approach has the potential to enhance cost-effective, durable composite powder production with broad applications in industries like aerospace and automotive. While our research currently focuses on stirring duration and guest particle loading, the application of the DOE approach lays the groundwork for future investigations into additional EA process parameters, such as pH value, particle size, and temperature to expand our understanding of efficient composite powder formation.