Metal powder feedstock evaluation and management for powder bed fusion: a review of literature, standards, and practical guidelines

Abstract

Metal powders are key to metal additive manufacturing technologies such as powder bed fusion. These powder feedstocks experience a range of forces and physical phenomena both during the powder bed fusion process and additional post-processing stages that can alter their composition and material properties. To evaluate such effects, these powders need to be characterized, tested, and analyzed at critical stages of their lifecycles. This paper provides a review of the current state of the art for powder evaluation methods and their applicability for powder bed fusion production. Methods are categorized by the properties they evaluate, either particulate or bulk properties. Industry standards are identified for each method if applicable and the advantages and disadvantages of each are defined. Effects of these properties on the flowability and spreadability of powders are synthesized and practical management guidelines are defined. This paper aims at providing an overview of powder evaluation for powder bed fusion, practical considerations for the development of powder test and evaluation programs, and provide insights for future research undertakings in the field.