An investigation of the effect of powder flowability on the powder spreading in additive manufacturing

Identification of the most reliable method to characterise powder flow behaviour in correlation with the conditions of powder spreading in additive manufacturing (AM) is still challenging. In this study, a number of standard and advanced flowability techniques were used to characterise the flowability of two grades of Ti6Al4V powder (gas atomized, GA, and hydride-dehydride, HDH) used for the powder bed fusion (PBF) based AM. In parallel, the powder spreading behaviour was characterised using an in-house spreading rig. It is found that GA powder has better spreading behaviour than HDH, owing to its better flowability due to the regular particle shapes. However, none of the flow test techniques investigated in this paper can offer a correlation between the dynamic powder flow and powder spreadability at varying speeds. The study in this work has revealed the shortcomings in correlating the flowability of powder and their spreadability under real process conditions.