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Computed X-ray Tomography of Powder Metallurgy Product for Rapid, Quantitative Size and Shape Distribution Analysis

Analysis of powder metallurgy powders is an important consideration in designing the appropriate forming and processing parameters for near-net-shape components and additive manufacturing in various industries, including aerospace and electrical connectors. Not only is the size distribution an important factor in determining the packing factor of the components, but also particle shape. Typically, the particles are assumed to be spherical, with no satellites, and sparse particle analysis is conducted. Often, differences in particle size distribution, and possibly the shape of the particles, may lead to differences in the density of the finished product and overall quality. In most cases, the particle size distribution is quantified using a two-dimensional (2D) process, e.g., scanning electron microscopy (SEM) imaging or optical particle size counter or even just a mechanical sieve. Methods that would provide a more representative characterization of the particles would benefit additive manufacturing component producers in the areas of quality control, product improvement, and computational modeling.