Study analyzes properties of ti6al4v powder for laser powder bed fusion, suggesting control measures for quality.
The performance of Laser Powder Bed Fusion (LPBF) is highly dependent on the quality of the metallic powder feedstock. This study characterizes a gas-atomized Ti6Al4V (Grade 5) powder, analyzing morphology, particle size distribution, flowability, true density, chemical composition, phase constitution, and thermal stability. Optical and SEM imaging revealed predominantly spherical particles with some irregular shapes and satellites. Particle size analysis showed that only 46.49% of the volume fell within the specified 5–22?µm range, contributing to poor flowability (Hausner Ratio 1.86; Carr Index 46%). True density (4.35 g|cm³) closely matched the theoretical value, indicating low internal porosity. SEM|EDS confirmed the alloy composition but detected elevated oxygen levels. X-ray diffraction revealed an a-phase structure, while thermogravimetric analysis showed thermal stability up to 400?°C, followed by gradual oxidation. The results emphasize the critical influence of powder characteristics on LPBF processability and highlight the importance of stringent powder quality control to ensure reliable outcomes.
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Costa et al. (2025) studied this question.