The present PPT is for use by students registered in MCL133.

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Lecture 04
Credits 3 (3-0-0)

(Continued)

Instructor: Dr. Sagar Sarkar

Friday (11:00 AM-12:00 PM) – Slot F

Characterization of Metallic Powders
Near Net Shape Manufacturing (MCL133)

1
 Recap
• Chemical composition & purity (OES/EDX/XRD)
• Particle shape, size and distribution (SEM)

• Particle porosity
• Surface topography
• Flowability

2
 Discussions

Gif Source: additivemanufacturing.media DOI: 10.1115/1.4045415

Layer thickness: 20 micron/ 40 micron/ 60 micron

What happens to the relatively bigger size particles (> layer thickness) after 1st layer ?

What happens after 2nd layer ?

3
 Discussions

https://www.researchgate.net/profile/Jie-Yin-
24/publication/337379180/figure/fig1/AS:834365063966720@1575939541471/a-
Morphology-and-b-Particle-size-distribution-of-the-Inconel-718-powder.png

https://www.researchgate.net/publication/350301282_Numerical_Simulation_of_the_Molten_Pool_of_a_Powder_Bed/
figures?lo=1

4
 Role of smaller size particles
Discussions

https://www.sciencedirect.com/science/article/pii/S2214860420309246#fig0035
 Particle Shape, Size and Distribution
Different types of interaction when a laser beam interacts with a particle

• Reflection

• Refraction

• Absorption

• Diffraction

Have a look: https://www.youtube.com/watch?v=ZFbs-sXF7Ss

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 Particle Shape, Size and Distribution

https://www.google.com/url?sa=i&url=https%3A%2F%2Fwww.thinkymixer.com%2Fen-gl%2Flibrary%2Freport%2Fmethod-of-particle-seze-
evaluation-of-ground-material%2F&psig=AOvVaw3nHAD0kKLK4pY1HfF7C-
s9&ust=1643262992289000&source=images&cd=vfe&ved=0CAsQjRxqFwoTCODKvu7dzvUCFQAAAAAdAAAAABAO

https://www.youtube.com/watch?v=ZFbs-sXF7Ss

7
 Particle Shape, Size and Distribution
Particle size distribution Particle surface topography
Laser diffraction to measure the particle size and particle size distribution

https://www.sympatec.com/fileadmin/_processed_/8/8/csm_Laserbeugung_OptischerAufbau_EN_362fa170f5.png

https://www.malvernpanalytical.com/en/products/product-range/mastersizer-range/mastersizer-
Have a look: 3000?campaignid=1525758893&adgroupid=61542231817&creative=332719882717&keyword=laser%20parti
cle%20analyzer&matchtype=b&network=g&device=c&gclid=CjwKCAiA3L6PBhBvEiwAINlJ9A9_Gr6lHZq
ycHXbaLU5D4F8eHU1hxJ8q9F-MnY8jaDIVqIJp_hrExoCr8MQAvD_BwE

8
 Particle Flowability
Funnel type: https://www.youtube.com/watch?v=kq56KxlLVK4
Laser diffraction based

Inter-particle friction as indicated by the angle of repose of a pile of powders poured

from a narrow funnel

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 Particle Flowability
Smaller particle sizes show steeper angles or larger particle sizes?

Finer
particles

Smaller particle sizes generally show greater friction

and steeper angles!

10
 Particle Flowability
Which shape has the lowest inter-particle friction?

Little friction
between
spherical
particles!

As shape deviates from Spherical shapes have the

spherical, friction between lowest inter-particle friction!
particles tends to increase

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 Particle Porosity & Density

True density: density of the true volume of the material

The density of the material if the powders were melted into
a solid mass
Bulk density/Apparent density: density of the powders in
the loose state after pouring

Which one is smaller?!

Because of pores between particles, bulk density is less than true density.

The lower apparent density of the powder, the longer will be compression stroke and deeper dies
will be required to produce a compact of given thickness and density.

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 Particle Porosity & Density

Packing factor = Bulk density

True density

Typical values for loose powders range between 0.5 and 0.7

How can we increase the bulk density?

• If powders of various sizes are present, smaller powders will fit into spaces
between larger ones, thus higher packing factor
• Packing can be increased by vibrating the powders, causing them to settle
more tightly
• Pressure applied during compaction greatly increases packing of powders
through rearrangement and deformation of particles

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 Particle Porosity & Density

Porosity

Ratio of volume of the pores (empty spaces) in the powder to the

bulk volume

In principle
Porosity + Packing factor = 1.0

The issue is complicated by possible existence of closed pores in

some of the particles

If internal pore volumes are included in above porosity, then

equation is exact

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 Particle Porosity & Density
Tap density
It is the ratio of the mass of the powder to the volume occupied by
the powder after it has been tapped for a defined period of time

Hausner ratio (H)

It is correlated to the flowability of a powder or granular material.
It is named after the engineer Henry H. Hausner

Hausner ratio (H) = Tapped bulk density

Freely settled bulk density
H > 1.25 – 1.4 , considered as poor flowability

Carr Index (C)

H= 100 / (100-C)
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Thank you

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