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Introduction to Metal Powder Characterisation

Webinars 08 June 2022

Metallic powders have grown in importance in recent years due to their use in additive manufacturing (AM) and other powder-related processes such as near net shape powder metallurgy hot isostatic pressing (NNS PM HIP). Several studies have demonstrated that powder characteristics play a crucial role on the final materials properties, thus powder characterisation represents a crucial step in the production of PM components. Additionally, metal powders are manufactured in batches leading to physical and chemical inconsistency, which results in high scatter band in materials’ properties. The primary considerations, in terms of metal powder characteristics for AM, is to ensure consistent powder bed packing and constant flow rate, dependent on the specific AM process. Packing density and flowability of metal powders depend on the powder manufacturing method, specified powder size range, particle size distribution (PSD), shape and morphology of the particles. These characteristics need to be determined to ensure consistency in properties of the produced parts.

This webinar will discuss the characterisation methods available for metal powders. The effect of different powder manufacturing methods on the powder properties will be presented along with some case studies on how differing metal powder properties affect the structural integrity of the produced AM components.

Speakers

Kostas Georgilas - Project Leader, Thermal Processing Technologies

Kostas Georgilas

Project Leader, Thermal Processing Technologies

Dr Konstantinos (Kostas) Georgilas is a Project Leader in the Thermal Processing Technologies section at TWI Ltd, having joined as a PhD student in 2016 and a Project Leader in 2019.

He has an M.Eng in Chemical Engineering from the Aristotle University of Thessaloniki (Greece), an M.Sc in Advanced Material Manufacturing from the University of Nottingham and a PhD in Engineering from the University of Aberdeen.

Kostas has 6 years experience around the material properties before, during and post powder bed fusion AM processes. Particular specialisations are the characterisation of metal powders and the post-thermal heat treatment of AM material.

Alessandro Sergi - Project Leader, Thermal Processing Technologies

Alessandro Sergi

Project Leader, Thermal Processing Technologies

Alessandro Sergi started his role as Project Leader at TWI in September 2021. He is currently completing his PhD on Powder Metallurgy Hot Isostatic Pressing of high temperature materials (PM) at TWI Ltd and the University of Birmingham, with particular focus on the influence of powder characteristics on microstructure and mechanical properties of as-HIPed parts.

Before his PhD, Alessandro obtained a BSc and MSc degree in Mechanical Engineering at the University of Calabria (Italy).

During his career, he has developed expertise in powder metallurgy, hot isostatic pressing, metallurgy of Ni-based superalloys and refractory metals, with particular focus on how powder characteristics affect the final properties in powder-related manufacturing processes.

Raja Khan - Technology Consultant, Thermal Processing Technologies

Raja Khan

Technology Consultant, Thermal Processing Technologies

Dr Raja Khan CEng FIMMM, FWeldI has a background in metallurgy, materials science and manufacturing with 27 years research & development experience by working in various industries and R&D organisations. He is currently working as technology Consultant in the Thermal Processing Technologies (TPT) section at TWI Cambridge since 2014. His research work is mainly focused on advanced manufacturing (additive manufacturing, near net shape powder metallurgy hot isostatic pressing), materials joining technologies, powder characterisation, post thermal processing, surface engineering and currently working on multidisciplinary projects funded by both private and public sector bodies. He is a member of ASME Standards AMS additive manufacturing metal committee. He is also currently supervising 7 PhDs mainly research related to PM based advanced manufacturing technologies.

For more information please email:


contactus@twi.co.uk