QUALITY CONTROL FOR ADDITIVE MANUFACTURING
Particle size, shape & powder chemistry fully automatically analyzed using SEM-EDX
Additive manufacturing
Powder quality is crucial
In additively manufactured components, many defects can be traced back to the quality of the starting powder. Poor powders lead to the formation of pores, inclusions, microcracks and undesirable surface roughness. Round, homogeneous particles are ideal for additive manufacturing. In addition, the particles must be chemically identical and the powder must be free of foreign substances.
Optical quality control is limited
Many users rely on purely optical methods for the quality control of powders. The reason is simple: the analysis is fast and the systems are cost-effective.
However, in an environment that increasingly demands a zero-defect strategy in additive manufacturing (aerospace, medical technology), this approach is not sufficient. Optical quality control neglects the increasing demands on powder chemistry and contamination.
SEM-EDX analyzes size, shape & chemistry
The SEM-EDX method has proven to be effective for extended quality control, including powder chemistry. In this method, particle size and shape are determined by imaging in a scanning electron microscope (SEM). At the same time, the composition of the particles is individually determined using elemental analysis (EDX).
The best part: The procedure is automated for the analysis of many particles; the user only has to prepare the sample, insert it into the device and start the program.
Application example
Titanium alloy powder Ti-6Al-4V
The size and morphology of each particle is analyzed individually and fully automatically.
The histogram shows the results of the size measurement converted into volume percent.
The diagram shows the proportions of the morphology classes for large and small particles.
With the help of EDX element analysis, the particles can be individually assigned to a class. In the case of defective Ti-6Al-4V powders, pure titanium particles are often found, which have a negative effect on the structure. Organic impurities are also common and lead to an increase in temperature during laser welding. Carbon residues are burned into the structure.
Phenom ParticleX
Developed for Fast Powder Analysis
For the rapid SEM-EDX analysis of metal powders in additive manufacturing, the sample only needs to be prepared on a suitable substrate (by vacuum filtration or air dispersion). The ParticleX works in a low vacuum to prevent charging under the electron beam. This eliminates the need for the annoying coating of the sample. In addition to powder analysis, the device also offers the option of fully automatically analyzing inclusions and pores in the structure.
ParticleX also analyses inclusions
ParticleX is also ideal for the automatic analysis of inclusions in the structure. Each inclusion is imaged individually, its size is measured and its chemistry is determined using EDX element analysis.
Highlight applications