The Influence of Spreading Metal Powders with Different Particle Size Distributions on the Powder Bed Density in Laser-Based Powder Bed Fusion Processes

Published

March 28, 2018

Author(s)

Gregor Jacob, Christopher U. Brown, Alkan Donmez

Abstract

In laser powder bed fusion (LPBF) processes the powder size characteristics, like particle shape, particle size (PS), and particle size distribution (PSD), and the resulting powder bed density (PBD) are key influencing factors of the built material properties. To better understand the correlations between the powder size characteristics and the powder properties influencing the LPBF process, apparent density (AD), flowability, and PBD were measured corresponding to two commercial metal powders with different PS and PSD. The powder samples were taken from different locations on the build platform to also investigate the variations of these powder characteristics resulting from the spreading process by the stiff recoater blade. It was shown that the PS and PSD had a significant effect on the AD and the PBD. Powders with a wide PSD and a high proportion of the powder with a particle size fraction in the range of the effective powder layer thickness, lead to a higher PBD than powder with a high proportion of finer particles. No significant differences in PS and PSD were observed as powder was pushed across a build plate by the recoater blade.

Citation

Advanced Manufacturing Series (NIST AMS) - 100-17

Report Number

100-17

NIST Pub Series

Advanced Manufacturing Series (NIST AMS)

Pub Type

NIST Pubs

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DOI Link

Keywords

additive manufacturing, apparent density, powder bed fusion, selective laser melting, selective laser sintering, powder bed density, metal powder, powder layer, powder spreading, powder layer thickness, particle size distribution

Citation

Jacob, G. , Brown, C. and Donmez, A. (2018), The Influence of Spreading Metal Powders with Different Particle Size Distributions on the Powder Bed Density in Laser-Based Powder Bed Fusion Processes, Advanced Manufacturing Series (NIST AMS), National Institute of Standards and Technology, Gaithersburg, MD, [online], https://doi.org/10.6028/NIST.AMS.100-17 (Accessed October 24, 2025)