Abstract
Powder-based additive manufacturing (AM) technologies are capable of producing high-performance parts for a diverse set of applications. Many AM processes require specific tolerances on feedstock powder to be successful, necessitating high-quality, precise measurements of particle size distribution (PSD) and morphology. This study investigates the use of several powder PSD and morphology measurement methods—including laser diffraction (LD)-based and static image analysis (SIA) techniques—for AM applications. Four AM powders of varying size and shape were tested to compare the influence of data collection methodology on reported powder characteristics. Results indicate that a disparity exists between the PSD and powder morphology data collected using the three method types evaluated, particularly when measuring fine and irregular powder particles. Considering the advantages and disadvantages of both SIA and LD-based methods, consistent use of methodological approach is recommended when analyzing powder PSD and morphology for AM applications.
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