Quantitative Characterization of Metal Powder Morphology, Size Distribution, and Flowability for Additive Manufacturing

Murtaza H.A. Mukhangaliyeva A. Golman B. Perveen A. Talamona D.
October 2024 Springer

Journal of Materials Engineering and Performance
2024 #33 Issue 20 10853 - 10867 pp.

The properties of the powder utilized in powder bed-based additive manufacturing are crucial in determining both the process parameters and the final quality of the fabricated components. Therefore, it is essential to assess powder characteristics, particularly particle morphology, size distribution (PSD), and rheological properties. This study aims to quantitatively characterize the PSD, morphology, and flowability of metal powders commonly used in additive manufacturing, such as AlSi10Mg, Inconel-718, Ti6Al4V, titanium, and stainless steel. To achieve this, we utilize a range of PSD models to accurately fit the measured size distributions based on volume and number, followed by conducting statistical analyses to determine the best-fitting models. Furthermore, we conducted a shape analysis using the elliptic Fourier series to characterize particle morphology quantitatively. Additionally, we examined the correlations between the powder rheological properties, measured by a Hall flowmeter, tapped density tester, and FT4 powder rheometer, and the PSD and shape indices using Spearmans coefficient test.

additive manufacturing , metal powder , particle size distribution , powder morphology , rheological properties , size distribution models, shape indices

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Department of Chemical and Materials Engineering, School of Engineering and Digital Sciences, Nazarbayev University, 53 Kabanbay Batyr, Astana, 010000, Kazakhstan
Department of Mechanical and Aerospace Engineering, School of Engineering and Digital Sciences, Nazarbayev University, Astana, 010000, Kazakhstan

Department of Chemical and Materials Engineering
Department of Mechanical and Aerospace Engineering

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