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Powder Metallurgy and Additive Manufacturing
The Powder Metallurgy and Additive Manufacturing Laboratory provides advanced facilities for the characterisation of powdered materials and the development of additively manufactured components. The laboratory supports both academic research and industrial collaboration, focusing on the relationship between powder properties, processing conditions and final component performance.
Equipped with state-of-the-art instrumentation, the laboratory enables detailed analysis of powder morphology, particle size distribution, flow behaviour, and compaction characteristics. These insights support optimisation of powder-based manufacturing processes, particularly laser powder-bed fusion (L-PBF) additive manufacturing.
Core Competencies
Powder Characterisation
The laboratory specialises in comprehensive characterisation of powdered materials used in powder metallurgy and additive manufacturing processes. Measurements include:
- Particle size distribution
- Particle morphology and shape analysis
- Powder flowability
- Apparent and tap density
- Powder cohesion
- Powder packing and compaction behaviour
Advanced analytical methods are used to generate quantitative data, enabling data-driven interpretation of powder behaviour and prediction of performance in manufacturing processes.
Additive Manufacturing (Laser Powder-Bed Fusion)
The laboratory supports additive manufacturing using the Laser Powder-Bed Fusion (L-PBF) process. This technique selectively melts layers of metal powder using a high-energy laser to build complex three-dimensional components.
Research focuses on:
- Process parameter optimisation
- Powder behaviour during spreading
- Microstructure development
- Defect formation and mitigation
- Mechanical performance of additively manufactured components
The integration of powder characterisation and process development enables a deeper understanding of how powder properties influence print quality and material performance.
Applications
The laboratory supports research and development in areas including:
- Metal additive manufacturing
- Powder metallurgy
- Aerospace materials
- Automotive components
- Advanced materials development
- Process optimisation for powder-based manufacturing
Laboratory Capabilities
Advanced Powder Characterisation
The laboratory provides comprehensive testing of powdered materials used in additive manufacturing and powder metallurgy. Capabilities include:
Particle Size and Morphology Analysis
Particle size distribution and particle shape strongly influence powder flow and packing behaviour. Automated optical imaging systems provide high-resolution analysis of particle morphology and size distribution.
Powder Flowability Testing
Powder flowability determines how reliably powders spread during additive manufacturing. Dynamic testing methods measure the angle of repose, cohesion, and flow characteristics under rotating conditions.
Density and Packing Measurements
Apparent density, tap density, and powder compaction behaviour are measured using automated instrumentation compliant with established testing standards.
Standardised Powder Testing
The laboratory can perform testing compliant with recognised international standards, including:
- ASTM B212
- ASTM B213
- ASTM B417
- ASTM B527
- ASTM B964
- ISO 3923
- ISO 4490
These tests ensure reliable and reproducible measurement of powder properties used in research and industrial quality control.
Research Process Flow
Research in the Powder Metallurgy and Additive Manufacturing Laboratory typically follows a structured workflow:
- Representative Powder Sampling
Powder batches are first sampled using a rotating riffle sampler to ensure representative and statistically reliable material selection.
- Powder Preparation and Conditioning
Samples may be sieved to remove oversize particles or contaminants and prepared for analytical testing.
- Powder Characterisation
The powder is characterised through:
- Particle size distribution analysis
- Particle morphology measurement
- Flowability testing
- Density and compaction measurements
- Data Analysis
Experimental data are analysed to understand powder behaviour and identify key parameters affecting manufacturing performance.
- Additive Manufacturing Trials
Selected powders are processed using laser powder-bed fusion to produce test components under controlled conditions.
- Post-Processing and Evaluation
Manufactured components are evaluated to determine relationships between powder properties, process parameters and material performance.
Major Equipment and Instrumentation
Malvern Morphologi 4-ID
The Morphologi 4-ID is an automated system used for detailed particle characterisation. The instrument disperses powdered samples and captures high-resolution optical images of individual particles to determine:
- Particle size distribution
- Particle morphology
- Shape characteristics
The system analyses materials with particle sizes ranging from 0.5 µm to 1500 µm.
It is also equipped with Morphologically Directed Raman Spectroscopy, enabling targeted Raman analysis of individual particles to identify chemical composition directly from particle surfaces.
GranuTools GranuPack
The GranuPack system measures the apparent and tap density of powdered materials using automated and repeatable testing procedures.
Key capabilities include:
- Measurement of powder packing behaviour
- Quantification of powder compressibility
- Automated tapping sequences for repeatable measurements
The system improves upon traditional methods defined in ASTM B527, while also supporting measurements compliant with the standard.
GranuTools GranuDrum
The GranuDrum measures powder flowability using a rotating drum system.
This instrument evaluates:
- Dynamic angle of repose
- Powder cohesion
- Flow behaviour under varying rotational speeds
The dynamic measurement approach provides a more realistic representation of powder behaviour during industrial processing and additive manufacturing.
Rotating Riffle Sampler
The rotating riffle sampler ensures accurate and representative sampling from larger powder batches.
Representative sampling is essential to ensure reliable and repeatable experimental measurements. The sampling process is aligned with ASTM B215-20.
Sieve Shaker and Laboratory Test Sieves
Laboratory sieves and mechanical sieve shakers are used to classify powders and remove oversized particles or contaminants from powder batches prior to testing or processing.
Hall Flowmeter
The Hall Flowmeter is used for standardised measurement of powder flow rate and apparent density using Hall and Carney funnels.
Testing is conducted according to recognised standards, including:
- ASTM B212
- ASTM B213
- ASTM B417
- ASTM B964
- ISO 3923
- ISO 4490
These tests are widely used for qualification of metal powders used in powder metallurgy and additive manufacturing.
MLab 200R
The MLab 200R is a compact laser powder-bed fusion additive manufacturing system designed for research and development of metal additive manufacturing processes.
Key features include:
- Precision powder deposition
- Controlled laser melting of metal powders
- Small-scale component fabrication for research studies
- Process parameter development and optimisation
The system allows investigation of the relationship between powder properties, process parameters, and final component quality.
Typical Research Activities
The laboratory supports a wide range of research topics, including:
- Characterisation of powders for additive manufacturing
- Effects of powder morphology on flowability and packing
- Relationship between powder properties and build quality
- Development of new metal powders for AM processes
- Optimisation of L-PBF processing parameters
- Investigation of powder reuse and recycling effects
- Powder quality control and qualification
Research outputs support both fundamental materials science and industrial process optimisation.
Links to Other Research Competencies
Powder research in this laboratory connects with a range of complementary research capabilities, including:
- Materials characterisation and microscopy
- Mechanical testing of manufactured components
- Metallurgical analysis and microstructure evaluation
- Machine learning and data analytics
- Advanced manufacturing technologies
By integrating powder characterisation with downstream manufacturing and materials analysis, the laboratory provides a comprehensive research platform for powder-based manufacturing technologies.
Contact the Materials Processing Institute
Enquire about services, facilities, and expertise.
