Processes to Produce Powder: Air classification, Atomization, Chemical deposition, Granulation, Milling
Atomization: the dispersion of a molten metal into particles by a rapidly moving gas or liquid stream or by mechanical means.
Apparatus wise parameters of powder characterization
1. Flow Measurement
Flow Rate: The time required for a powder sample of standard weight to flow through an orifice in a standard instrument according to
a specified procedure.
Test Standards Effect in Process Parameters affect Flow Rate
ASTM B213 - Hall flow Shorter time reported for Shape - the more spherical the powder, typically the better it will flow
(free flowing powders), this test means that the PSD – a broad PSD powder typically flows better than a monosize PSD
ASTM B964 - Carney flow powder flows more easily powder
(non-free flowing powders) Particle size has a significant influence on flow – larger particles are
generally more free flowing than smaller particles
Moisture content in powders can reduce flow due to capillary forces acting
between particles
Flow properties often show a dependency on the packing density at the
time of measurement – powders with a higher packing density are less free
flowing than powders with a lower packing density
Apparent Density: The mass of a unit volume of powder, usually expressed as grams per cubic centimetre, determined by a specified
method
Test Standards Effect in Process Parameters affect Apparent Density
ASTM B212 - Hall flow A powder that packs easily (under gravitational force only) PSD will also play a role; in the case of
(free flowing powders), to a high density implies that it can be moved/spread with a broad PSD powder, the smaller
ASTM B417 - Carney flow the result that there is minimal void space between the particles can fit in the space between
(non-free flowing powders) powder particles. Reducing the void space between powder larger particles, while a monosize PSD
particles during powder spreading will make it easier to powder does not have this opportunity.
subsequently densify the powder.
In general, the higher the apparent density of a powder, the Powder shape will influence this
better it should process for Metal AM provided other characteristic, because the more
attributes like particle size remain the same. spherical the powder, typically the
better it will pack together.
Angle of Repose (ref. A): The basal angle of a pile formed by powder when freely poured under specified conditions onto a horizontal
surface
Effect in Process: Smaller the angle value better the flowability of powder
2. Tap Density
Bulk Density: The mass per unit volume of a powder under nonstandard conditions, for example, in a shipping container.
Tap Density: The apparent density of the powder in a container that has been tapped under specified conditions
Test Effect in Process Parameters affect Tap Density
Standard
ASTM B527 By exposing the powder to tapping it Powder shape will influence this characteristic, because the more
maximizes the packing density of the powder spherical the powder, typically the better it will pack together.
without applying direct force.
A high relative tap density value should be Particle-size distribution will also play a role; in the case of a broad particle
helpful for powder spreadability and uniformity size distribution powder, the smaller particles can fit in the space between
during the Metal AM process. larger particles, while a monosize particle-size distribution powder does
not have this opportunity.
Compressibility Index or Carr Index (ref. A): Ability of a powder to decrease in volume under pressure
Effect in Process: Smaller the index value better the flowability of powder
Hausner Ratio (ref. A): It is the ratio of tap density to bulk density of powder
Effect in Process: Smaller the ratio value better the flowability of powder
3. Particle Size Distribution: The percentage by weight, or by number, of each fraction into which a powder sample has been
classified with respect to sieve number or microns
Test Effect in Process Effect in Product Parameters affect
Standards PSD
ASTM B214 It will influence the minimum thickness that can Coarser the particle size give more surface
be spread while building a powder bed. roughness, low density and more porous.
It will also directly affect the densification in Finer the particle size tends to be more
sintering for the Metal AM processes that cohesive and therefore less free flowing and
require consolidation in a furnace also issues with laser interaction.
Reference A: Hausner Ratio & Carr Index or Compressibility Index (%) and Angle of repose
Hausner Ratio Carr Index or Angle of repose
Flow character Compressibility Index (%) (in degree)
Excellent 1.00-1.11 ≤10 25-30
Good 1.12-1.18 11-15 31-35
Fair 1.19-1.25 16-20 36-40
Passable 1.26-1.34 21-25 41-45
Poor 1.35-1.45 26-31 46-55
Very poor 1.46-1.59 32-37 56-65
Non-flow >1.60 >38 >66