Particle size analysis of metal powders: problem or compliance

The distribution of particle sizes directly influences the behavior of a metal powder during storage, transport, dosing, and processing. An out-of-specification, overly broad, or changing particle size distribution can contribute to issues with flowability, segregation, densification, or production consistency. A particle size analysis can characterize the size distribution, quantify differences between batches, and assess compliance with the requirements defined in your specifications.

Comparing particle size distribution curves and distribution indicators can reveal a shift in particle size, broadening of the distribution, or an unexpected particle fraction. These results provide objective information for deciding whether to accept a batch, directing a quality investigation, or adjusting an internal specification.

The choice of method depends on the expected particle size range, particle morphology, dispersion behavior, and the compliance criteria to be verified. Depending on the need, the study may rely on sieve separation techniques or an instrumental measurement of particle size distribution. The protocol is defined with the client to ensure that the results can be compared with the applicable specification or reference standard.

The results are interpreted in light of the limits, particle size classes, or tolerances provided by the client. When the requirements have not yet been formalized, comparison with a reference batch, production history, or several supplier batches helps characterize the observed variability and define consistent control criteria.

The Filab laboratory supports industrial companies with their metal powder analysis, whether investigating a nonconformity, comparing a received batch with a reference batch, or qualifying a raw material. The approach is tailored to the nature of the powder, the particle size range under investigation, the available sample volume, and the expected decision: diagnosing a problem or compliance issue, supplier quality control, process optimization, or quality monitoring.

Particle size must be interpreted alongside the other relevant characteristics of the powder. As a complementary service, the Filab laboratory can guide you toward powder flowability analysis or metal powder reactivity analysis when these properties are involved in the issue observed.

Preparation and sampling determine the reliability of the interpretation. The Filab laboratory takes into account sample homogeneity, dispersion conditions, and the specific characteristics of the powder to prevent agglomeration or an inadequately represented fraction from distorting the assessment. Training in metal powder analysis can also help your teams better define their controls.

In the event of a discrepancy, particle size analysis can be the first step in a broader investigation. Filab laboratory can help guide investigations related to the material, the process and the defects observed. To analyse the interactions between testing and manufacturing, discover our support for industrial process audits.

To define a relevant testing programme, provide the type and designation of the powder, the quantity available, the expected particle size range, the compliance criteria, the context of any anomaly and previous results. Specifying the final application, storage conditions and batches to be compared enables Filab laboratory to propose a suitable approach. Contact Filab laboratory to define the tests, send your samples and receive a technical proposal.