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A new route for the synthesis of powder composites suitable for processing with laser additive manufacturing is demonstrated. The powder composites, consisting of micrometer-sized stainless steel powder, homogenously decorated with nano-scaled Y2O3 powder particles, are manufactured by laser processing of colloids and electrostatic deposition. Consolidated by laser metal deposition and selective laser melting, the resulting specimens show superior mechanical properties at elevated temperatures, caused by the nano-sized, homogenously distributed dispersoids.

Laser additive manufacturing of oxide dispersion strengthened steels using laser-generated nanoparticle-metal composite powders