Additive Manufacturing Powder Particle Size Distributions: Comparison of Histogram Binning Methods †

Abstract

Additive manufacturing powders require a well-defined particle size distribution (PSD) and spherical morphology to ensure good flowability. To simplify characterisation, powders can be prepared using standard metallurgical techniques followed by optical imaging of the cross-sectioned particles. Measured PSDs of particle sections are typically underestimates of the true PSD; hence, stereological corrections are required. Variations arise in the histogram binning methods (central binning versus upper limit binning) of commonly used stereological corrections. Although the results show some sensitivity to the binning method used, the GCO method seemed reasonably robust to changes in the binning method. However, authors are encouraged to follow the method as it is intended within the literature, which was found to be especially true when using Saltykov’s method.