Metallic powders: from rheology to the performance of engineered materials
What is additive manufacturing?
Complementary to traditional manufacturing procedures based on the removal of matter, additive manufacturing makes it possible today to achieve an unbeatable level of freedom during the designing process and exceptional implementation time. This technique is used in many applications, in very demanding fields such as aeronautics, medicine, space, defense…
Additive manufacturing consists of assembling a part by piling up successive layers of powder (mostly metallic powder), melted using a beam (either a laser or a beam of electrons).
The FILAB laboratory is ISO 17025 accredited by COFRAC for:
- specific surface area measurement using the BET method (according to ISO 9277) and particle size analysis by laser (according to ISO 13320, both liquid and dry methods),
- density measurement by helium pycnometry (according to ASTM B923 and ISO 12154),
- grain size determination (according to ASTM E112 and NF EN ISO 643) for bulk materials.
Analysis of metallic powders: why call on FILAB?
With extensive experience in implementing these different techniques, FILAB is able to assist you in analyzing your metallic powders and with our expertise of activities relating to additive manufacturing:
Chemical composition analysis of metallic powders using ICP-AES, ICP-MS and/or using C/S, O/N, and H elemental analyzers
Density measurements in accordance with the ASTM B527 and ISO 3953 standards
Granulometric analysis using laser granulometry in accordance with the ISO 13320 standard
Flowability testing in accordance with the ASTM B213, ISO 4490 and ASTM B964 standards
SEM FEG EDX or Optical Microscope morphological analysis
SAFRAN accreditation according to specifications Ma0015. SAFRAN has extended the scope of our accreditation to include the chemical and physical characterization of metal powders! This recognition further highlights our expertise in characterization and analysis of metal powders, enabling us to respond more quickly and reliably to our customers’ needs.
Instruments for the analysis of metal powders :
GranuHeap: measurement of the static properties of a metal powder (angle of repose, static cohesion index).
GranuDrum: measurement of flow properties (flow angle, dynamic cohesion index, angle of first avalanche, powder aeration).
GranuPack: measurement of the dynamic compaction of a metal powder (apparent density, tap density, Hausner ratio, densification dynamics).
GranuFlow: measurement of flow through orifices, a key indicator of powder flowability.
GranuCharge: measurement of the electrostatic properties of metal powders.
Why characterize your metallic powders?
This process is sensitive to changes in particle sizes and shapes in the powder being used. These geometrical characteristics impact the spread and compactivity of the material during the manufacturing process.
To ensure a certain level of quality for printed parts, metallic powders need to meet various requirements to be able to perform as intended. Integrated into the French NF E67-010 standard, specifying the technical requirements for metallic powders designated for use in additive manufacturing, the main parameters are:
- Particle Size Distribution usually measured with a laser granulometer in accordance with the ISO 13320 standard making it possible to determine conventional parameters such as D10, D50 and D90.
- Flowability characterized by the average time it takes a powder to flow through a calibrated Hall or Carney funnel in accordance with the ISO 4490/ASTM B213 and ASTM B964 standards respectively
- Bulk and tapped density are measured to characterize a powder’s capacity organize itself and purge trapped air. These tests are performed with a volumenometer inaw the ASTM B527 and ISO3953 standards. The Hausner ratio is the ratio of tapped density to bulk density.
- True density is measured with a pycnometer in accordance with the ISO 12154 or ASTM B923 standards. This value is used to determine theoretical density and the internal porosity of a powder
- Morphology is studied under a Scanning Electron Microscope (FESEM) and under an Optical Microscope to determine the granulomorphology, the sphericity and the agglomeration state of the powder
- Humidity, determined by gravimetry after a drying the sample in accordance with ASTM E1868
- Chemical composition of metallic powders, determined using spectroscopy techniques such as ICP-AES and ICP-MS or elemental techniques to quantify C, H, O, N, S elements.
Compliance with the requirements associated with these different characteristics allows metallic powders to achieve a low defect rate (porosity, inclusion, etc.) and a high level of compactness in the part being manufactured, which in turn results excellent mechanical properties
FAQ
Metal powder characterization refers to the set of analytical techniques used to determine the physical, chemical, and morphological properties of metal powders.
This includes particle size distribution, shape, density, flowability, moisture, and chemical composition — all key parameters for ensuring quality and consistency in additive manufacturing.
The performance of 3D-printed metal parts depends directly on the properties of the powder used. Proper characterization ensures uniform particle distribution, optimal flowability, and controlled porosity, resulting in stronger, more reliable parts with fewer defects.
FILAB follows recognized international standards such as ISO 13320 for particle size analysis, ISO 4490/ASTM B213 for flowability, ASTM B527 for density, and ISO 12154 for true density. These standards guarantee traceability and reproducibility of results.
FILAB analyzes a wide range of metallic powders used in additive manufacturing and traditional metallurgy — including titanium, aluminum, stainless steel, nickel, cobalt, and copper alloys.
The shape and surface condition of metal powder particles influence how layers are spread during additive manufacturing. Spherical and smooth particles improve flowability, compaction, and homogeneity, leading to parts with better mechanical strength and reduced porosity.
Yes. After several printing cycles, metal powders can degrade — oxidation, contamination, or changes in particle size can occur. Recharacterizing reused powders helps determine whether they still meet the standards for additive manufacturing or need to be replaced.
Physical characterization focuses on particle size, morphology, and density, while chemical characterization analyzes the composition and potential impurities. Both are essential to ensure consistent performance and prevent manufacturing defects.
It depends on your production frequency and quality requirements. For critical sectors like aerospace or medical, characterization is often done before each production batch or after every reuse cycle to ensure material reliability.
