Powder metallurgy andadditive manufacturing
Material characterization solutions

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3

Shaping the future
Powder metallurgy is an umbrella term that covers
a range of processes for manufacturing metallic
components from metal powders usually by first forming
a dimensionally stable compact and then sintering it. The
main processes include;• Press and Sinter• Metal injection molding

Metal powder manufacture
Additive Manufacturing is a relatively new techniquethat permits local fusing of metal powders using a laser,
electron beam, or by post-sintering adhesive bonded
powders.

Metal powders are common to all powder metallurgy
processes hence the powder manufacturing process andresultant powder properties are critically important andintrinsically linked.

The choice of powder manufacturing route depends onthe metal / alloy, the powder metallurgy process, and thepowder properties required for that process.

There are a number of reasons for using a powder
metallurgy process instead of a traditional process suchas machining. These include one or more of the following:

The main routes for manufacturing metal powders are:

• Particle size distribution• Significant cost savings• Hot/Cold Isostatic pressing• High dimensional accuracy• Additive manufacturing
Traditional powder metallurgy processes such aspress and sinter have been used to produce metallic
components since the 1920s while processes such as
Hot Isostatic Pressing (HIP) and Metal Injection Molding(MIM) have been employed since the 1960s and 70s
respectively.

• Minimal post processing• Good part to part reproducibility• Greater dimensional freedom andcompositional complexity• Key powder characteristics are:• Comminution of solid metal• Particle shape• Precipitation of a salt from solution• Micro-structure• Thermal decomposition of metal
carbonyl (Carbonyl process)• Surface condition• Elemental composition• Solid state reduction of metal oxide• Electrodeposition• Atomization of molten metal

In-size range frequency (%)• Reduced waste

Brazing
53 - 150 µm
Laser
cladding
45 - 75 µm
Representation of an
as-atomized particle
size distribution

Laser melting
15 - 45 µm
Electronbeam melting
45 - 106 µm

Powder metallurgy refers to the production
and working of metals as fine powders which
can be pressed and sintered to form objects.

Cold spray
5 - 45 µm
Metal injection
moulding <38 µm
Press and Sinter>45µm
Isostatic pressing(Whole distribution)

100
Particle diameter (µm)

10

1
2
3
4
1. Incident X-ray
2. Ejected electron
3. Electron from outer orbital takes it’s place
4. Fluorescent X-ray

X-ray fluorescence

X-ray diffraction

In an XRF experiment, a sample
is irradiated by X-ray radiation
which causes constituent atoms
to become ionized. In response
the sample emits fluorescent
X-ray radiation with discreteenergies and intensities that arecharacteristic of the elements
present and their quantities.

X-ray diffraction is a
non-destructive analyticaltechnique in which incident
X-rays are scattered by theatoms of a crystal to produce aninterference effect and resultant
diffraction pattern. The scattering
pattern provides information about
the identity, distribution and sizeof crystalline phases present in
the material.

Incident
X-rayθ

Diffracted
X-ray
θ

1000

Resultant
X-ray

4

5

Press and sinterAdditive manufacturing

Powder characteristics are important for press and sinter,as for other powder metallurgy processes, with particle
packing and apparent density of the powder blend
critical.
A lower apparent density gives greater compaction
and cold-welding of particles on pressing, resulting
in a stronger green body. Interparticle friction is also
important and facilitates contact, deformation anddensification of the structure during pressing.

Malvern Panalytical’s characterization solutions for Pressand Sinter can be used to:• Predict and control powder packing
to give the required volume reduction
and degree of cold-welding• Ensure optimum contact between
particles for more efficient sintering

Metal powder hardness also affects pressing
performance and can depend on phase composition andgrain size.

• Measure and control batch-to-batch
variability in the metallic powder• Ensure optimum flowability and packing in the die
to prevent defects in the sintered component• Ensure alloys have the correct elemental
composition and phase structure• Determine residual stress, strain
and texture of sintered parts

In powder bed fusion processes a metal powder layer
is applied to a building platform and a laser or electron
beam is used to selectively melt or fuse the powder. Aftermelting the platform is then lowered and the processrepeated continually until the build is complete. The
unfused powder is removed and either reused or recycleddepending on its condition.
The efficiency of powder bed additive manufacturing
processes and the quality of finished components islargely dependent on the flow behavior and packing
density of the powders.

Press and sinter is the most conventional
manufacturing method associated withpowder metallurgy and involves three basic
steps

1

2

3
Force

1. Powder blending - metal powder ismixed with a suitable lubricant

Powder loose

Green
compact

Powder feed
supplyRoller

Focal plane
detector

Sample
flow

Red
laser

SpatialfilterBackscatter
detectors

Powder fullypressed
Powder feedpistonWide-angle
detectors

Blue
light

Powder partiallypressedLarge-angle
detectors• Optimize atomization conditions to achieve desired
powder properties• Ensure powders have the correct elemental
composition and phase structure• Determine residual stress, strain and texture ofmanufactured components

Unfusedpowder

2. Die compaction - the powder blend is pressedin a die to form a compact ‘green body’
3. Sintering – the ‘green body’ is heated
to below its melting point to form
the sintered component• Identify suitable powders for machines with different
spreader or rake designs

Scanning
mirror4
Force• Ensure a consistent powder supply and prevent
variations in product quality• Predict and optimize powder packing density and flow
characteristics

The particle size directly influences these properties andis a key specification for this process, with the optimum
particle size being in the range 15-45 μm for SLM and45-106 μm for EBM for example.
Laser

Malvern Panalytical’s characterization solutions for
Additive Manufacturing can be used to:Laser diffraction

Automated imaging

In a laser diffraction measurementa laser beam passes through adispersed particulate sample andthe angular variation in intensityof the scattered light is measured.
Large particles scatter light at
small angles relative to the laser
beam and small particles scatter
light at large angles.

Automated imaging techniques
use a digital camera to capture 2D
images of a dispersed particulate
sample. Individual particle images
are identified using digital
thresholding techniques, and thenanalyzed to determine their size,
shape and other physical properties
such as transparency.

The angular scattering intensity
data is then analyzed to calculate
the size of the particles thatcreated the scattering patternusing the Mie theory of lightscattering.

Automated imaging instruments
typically measure tens to hundredsof thousands of particles in thesame amount of time needed tomeasure a very small number bymanual microscopy.

BuildchamberBuildpistonBuildobjectFused
powder6

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Metal injection molding

Isostatic pressing

The rheological properties of the feed-stock are of major
importance for MIM applications since they influence thehomogeneity of the molten feedstock, how well it flows
through the die into the mold cavity, and the mechanicalproperties of the green part on cooling.

Isostatic pressing is a forming process where pressure isapplied uniformly (using gas or liquid) to a hermeticallysealed container filled with compacted metal powder.
The benefits of isostatic pressing over press and sinterare equal compaction in all directions and more uniform
density in the final component.

Phase composition and crystallite size are also importantsince these can affect powder hardness and melt
properties which impact pressing efficiency and sintering
behavior.

Isostatic pressing can be performed at elevatedtemperatures (Hot Isostatic Pressing (HIP)) or at ambient
temperature (Cold Isostatic Pressing (CIP)).

• Predict and control packing density and minimize void
formation in the sintered part

Rheological properties are influenced by a number offactors including; binder molecular weight and structure;solids loading; particle size and shape; temperature andflow rate.
Most metals can be used in MIM if they have the correct
powder properties, including particle size and shape.
High packing densities are required, so spherical particles
with the correct size distribution are preferable, as are
smaller particles (< 38μm) that sinter more readily. Slightparticle irregularity can be beneficial to give mechanicalstrength to green and brown parts.

Malvern Panalytical’s characterization solutions for Metal
Injection Molding can be used to:• Optimize particle loading to minimize
part shrinkage and void formation• Ensure appropriate feedstock rheology duringmolding, and dimensional stability post-extrusion• Optimize binder properties including
molecular weight and structure for flow
behavior and debinding performance• Ensure consistent metal powder supply
with correct particle size, elemental
composition and phase structure

Malvern Panalytical’s characterization solutions for
Isostatic Pressing can be used to:

Although HIP is a direct manufacturing route for metalcomponents it can also be used for densifying parts fromother powder metallurgy processes.
Spherical powders with a relatively wide but consistentparticle size distribution are preferred for HIP as they givehigher fill densities. For CIP, some particle irregularity
may help increase cold-welding, ideally withoutcompromising powder flow and packing.

• Specify and control metal powder quality• Optimize powder flow in the mold and maintainprocess efficiency• Ensure powders have the appropriate phase structureand elemental composition

Metal powder

BinderInjection molding

Feedstock

Oxidation
Powderedsample300°C

Weighing

Melting

FusionT°C

Decomposition
Melting

Mixing1100°C

MixingOxidationTime

Accurate
data

Multi
stage
coolingReleasingagent injection
Casting

Stable glass
beads

Cooling

DebindingSintering

Fill container withmetal powder

Heat under vacuum
to remove volatilecontaminants

Sample preparation
by fusion

Gel Permeation
Chromatography

Fusion is a sample preparation
method developed in the mid 50s.
It involves dissolving a fully oxidized
sample (at high temperature) in asolvent (a flux) in a crucible. The
melted mixture is agitated andpoured into a mold to create a glass
disk for XRF analysis. It can also be
poured into a beaker to create asolution for AA or ICP analysis. Oneof the main advantages of using
fusion in the preparation of metals isthat the technique is not affected bymineralogical or particle size effects,
thus enhancing the precision andaccuracy of XRF results.

Gel Permeation Chromatography(GPC) is an analytical technique that
separates dissolved maro-moleculesby size based on their elution fromcolumns filled with a porous gel.
When GPC is coupled withlight scattering, viscometerand concentration detectors(known as triple detection), it
can measure absolute molecularweight, molecular size and intrinsic
viscosity, and generate information
on macromolecular structure,
conformation, aggregation andbranching of polymers and waxes.

Hermetically seal
container

T=0

T=1

T=2

Apply pressureand heat

T=3

T=4

T=5

T=6

Remove sinteredcomponent

T=7

Flow

Mixing

Dissolution
solvent
Component A
Component B
Sample solution
Eluent / Mobile
phase

Chromatogram
Retention timeGel = Stationary
phase (packing
material)89What do your customers say?

Morphologi 4Wall Colmonoy invest in Morphologi 4 to improve their
metal powder products and manufacturing processes

Direct measurement of metal powder size and shape

Wall Colmonoy is a leading global materials
engineering group of companies engaged in
the manufacturing of Colmonoy® and Wallex®
surfacing and Nicrobraz® brazing products,
precision castings, coatings, and engineered
components across aerospace, automotive,
oil & gas, mining, energy and other industrial
sectors. Headquartered in Madison Heights,
Michigan, Wall Colmonoy have been an
established name in metallurgy since 1938,
with several sites in the US and European
headquarters in Swansea, UK.

The Morphologi 4 is an advanced yet easy-to-use, particle
characterization tool for measuring particle size and shape from 0.5
microns to several millimeters. The instrument offers the flexibility
required for R&D and troubleshooting applications, as well as the userindependent results and validation required for automated QC analysis.

Wall Colmonoy manufactures over 500 different
metal powder products at their Pontardawe facility in
Swansea and have a comprehensive suite of analyticalequipment for characterizing their powders: including
laser diffraction, chemical analysis, rheometry, optical
microscopy and electron microscopy. With a recent
move into Additive Layer Manufacturing, where powder
properties such as particle size and shape are often
more critical, there was a need to expand their analyticalcapabilities. “We know that particle shape directly
influences Additive Layer Manufacturing performanceand our customers expect a high-quality product withthe correct size distribution and a spherical morphology”
said Tom Roblin, Process Engineering Manager. “We have
manual microscopy and electron microscopy which allow

us to qualitatively check the products we manufacture
but we also needed a technique that could provide
quantitative data on a statistically representative sample.”
The technical team recognized that an automated opticalimaging platform capable of analyzing a large number ofparticles was required. They also needed image analysis
capabilities that could automatically quantify the size andshape distribution of those particles. “We identified threeplatforms that we thought could meet our requirements.
This included two Dynamic Imaging systems and theMorphologi 4 Static Imaging system from Malvern
Panalytical” said Roblin. “While Dynamic Imaging was able
to analyze a larger sample volume, the superior image
clarity provided by the Morphologi 4 was of greater
importance to us and also gave more consistent results”.

For many powder metallurgy applications particle shape can be just as
important as particle size. The Morphologi 4 reports shape information
using parameters such as elongation, circularity, convexity to quantify
particle irregularity and surface roughness. More efficient than manual
microscopy and electron microscopy, automated imaging provides
statistics on tens of thousands of particles.

The Morphologi 4 has found multiple applications within
the laboratory, not just for Additive Layer Manufacturing
powders, but for many of their other products also.
“Morphologi 4 is used to quantitatively measure theparticle shape of our atomized alloy powders. By
investing in this measurement equipment, we canbenchmark and improve our current processes andproducts.” said Roblin. “It will also aid in the developmentof a new range of Wall Colmonoy powders for Additive
Layer Manufacturing. For us, it is a valuable tool thatprovides clear images, quantitative analysis andconsistent results.”

RoughSmoothRegularElongated“Morphologi 4 is frequently used for
optimising atomisation conditions andevaluating the impact of process changes on
powder properties. It is a valuable tool thatprovides clear images and consistent results.”

Tom Roblin

Wall Colmonoy

FeaturesBenefits

Particle size range from 0.5 μm to 1000 μm

Make size measurements of powders for all powder metallurgy applications

Measurement of non-spherical particles
in terms of their length and width

Provides a more relevant size measurement of irregular particles

Automated image analysis that reports
a range of shape parameters

Quantify particles in terms of the degree of irregularity or surface roughness

Automation of manual methods
such as microscopy

Perform microscopy measurements faster and lesssubjectively, while freeing up resource

Integrated dry powder dispersion unit

Easy, reproducible sample dispersion which is
critical to achieving meaningful results

Optimized microscope optics and highsignal to noise CMOS camera

Generation of high quality particle images and image analysis data

Automated SOP control from sample
dispersion to results analysis

Simple, intuitive operation and robust, repeatable measurement protocols

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Mastersizer 3000+

OMNISECClass-leading performance with added intelligence

The most advanced multi-detector GPC/SEC system

The Mastersizer 3000+ is the next evolutionary step forthe world’s favourite particle sizing instrument, used bymany thousands of companies and research institutes
across a wide range of industries.

Based on the principle of laser diffraction, theMastersizer 3000+ addresses many of the disadvantagesof traditional sieve analyses for quality control:

OMNISEC is a Gel Permeation Chromatography (GPC)/ Size Exclusion Chromatography (SEC) system for themeasurement of absolute molecular weight, molecularsize, intrinsic viscosity, branching and other parameters.

OMNISEC can accurately measure the most importantcharacterization parameters, including:

Combining impressive sizing performance with a range
of intelligent and user-friendly software features, theMastersizer 3000+ is designed to make achieving
accurate particle size results the easiest it has every
been.

• Increased measurement range including veryfine particles.

The system includes OMNISEC RESOLVE, the integrated
GPC/SEC module, OMNISEC REVEAL, the integrated
multi-detector module and OMNISEC software, for thecharacterization of synthetic and natural polymers.

• Intrinsic viscosity and molecular structure• Faster and simpler analysis• Better measurement resolution for improved
product quality• Absolute molecular weight and molecular weight
distribution• Trouble free maintenance‘Since we purchased OMNISEC, we’reable to deliver more sensitive GPC data,so our ability to support decisions arounddifferent suppliers and troubleshooting
has been directly enhanced.’“We’ve been using theMastersizer 3000 for almosta year and our throughput has
increased more than we could
have imagined. The repeatability
is such that multiple analyses
overlaid appear as one distribution,and the software is extremely robust.”

Dr Kirt DurandSyngenta

Justin Hoover

Metals and Additives LLC

FeaturesBenefits

Measure particles in the size range 0.01 – 3.5 mm

Enable accurate measurement of almost any metal powder, irrespective of finenessand formulation

High accuracy, repeatability and reproducibility(<1% variation)

Verifiable instrument-to-instrument performance that you can rely on

Wet and dry dispersion

Improved flexibility in measuring your samples

Easy sample loading and cleaning

Reproducible dispersion with minimal sample-to-sample contamination

Rapid measurements (<20 sec)

Increased throughput/productivity and more efficient process control

TCP/IP or Autolab driver remote control
via Malvern LinkTM II

Feed results directly to the plant process control system

Modern and intuitive software interface

Live data monitoring, streamlined method development and built-in expert advice

Meets all the recommendations for ISO13320

Guarantees quality and complianceHigh quality particle images and complementary
shape data from an optional dynamic imaging
analysis accessory

Increased understanding of particle properties impacting flowability andpacking characteristics.
Oversized particle detection.

FeaturesBenefits

Highly sensitive light scattering (LS) detector

Measure molecular weights of polymers, oligomers and waxes down to 200 g/mol

Integrated differential viscometer

Measure intrinsic viscosity (IV) to investigate molecular structure and branching

Temperature controlled detectors

Achieve better baseline stability for improved accuracy and sensitivity

Workflow oriented software

Makes GPC/SEC measurements and analysis as easy and intuitive as possible

Integrated column oven

Improve separation quality and resolution

Refractive Index (RI) detector

Measure the concentration of almost any solute

Triple detection (RI, IV and LS)

Combine data to determine as hydrodynamic radius (Rh),radius of gyration (Rg) and Mark-Houwink parameters

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EpsilonZetiumBenchtop XRF spectrometers for simple elemental analysis

Floor-standing XRF for elemental excellence

X-ray fluorescence (XRF) is routinely used by metal
powder producers and component manufacturers
for determining the elemental composition of
metal alloys and for detecting the presence ofcontaminants. Elemental composition is particularly
important for alloys since small variations in theconcentration of alloying elements can affect its
chemical and physical properties, including strength,
hardness, fatigue life and chemical resistance.

Designed to meet the most demanding process control
and R&D applications, the Zetium spectrometer leads themarket in high-quality design and innovative features forquantitative analysis of elements ranging from beryllium(Be) to americum (Am), and is the preferred choice
when light element analysis and analytical precision isimportant. The modular design also allows for various
task-oriented enhancements to meet specific application
requirements.

The Epsilon range of Energy Dispersive X-ray
fluorescence (EDXRF) analyzers are capable ofsimple element identification and quantificationfrom sodium (Na) to americium (Am). They are easy
to operate, compact and X-ray safe instruments
without the need for additional chemicals.
Considerable savings in time and cost are two of
the many benefits EDXRF can bring compared toalternative analytical techniques such as ICP.

Zetium uses SumXcore technology which brings together
the benefits of WDXRF (Wavelength Dispersive) andEDXRF (Energy Dispersive) XRF with unique advantages
for the analysis of metals, including:• reduction in analysis time and improved precision• identification of unexpected elements in samples
For inclusion or contaminant detection, small spot
mapping and elemental distribution analysis can be
performed.

“Calibrates well to levels we look at.
Software is very intuitive andproduct support is great from theirdiverse application specialists.”

Riley Perkins

Freeport McMoran“Very easy to use. Reproducible
analysis. Very user-friendly.”Ivan Boninsegna

Aquafil S.p.a.
FeaturesBenefits

FeaturesBenefits

Analysis with/without reference standards

Analysis with/without reference standards

Can be calibrated with reference materials for most accurate
data or without for samples with unknown composition

Can be calibrated with reference materials for most accurate
data or without for samples with unknown composition

Versatile sample presentation

Can analyze sample types including liquids and slurries, pressed
powders, loose powders, fused beads and irregularly shaped objects

Can handle sample types including pressed powders, loose
powders, fused beads and irregularly shaped objects

High-capacity sample changer

High-throughput analysis of up to 240 samples per 8-hour shift

Versatile sample presentation
Both systems have compact design with Epsilon 1
having a built-in computer and touchscreen.

Requires less bench space and allows for easy anddirect instrument operation in the lab or at-line

System enhancement packages

Can be easily adapted and upgraded tomeet future testing requirement

Epsilon 4 has optional SDDUltra detector
for ultra light element analysis

Analysis of ultra light elements such as carbon,
nitrogen and oxygen down to 1 wt%

SuperQ software with Virtual Analyst

Simple and intuitive task-oriented workflow
with expert guidance for ease-of-use

Epsilon 4 has a 10-position removablesample changer with spinner

Automatic processing of sample batches and minimalerrors caused by non-homogeneity of sample

Small spot analysis with elemental mapping

Determine spatial distribution of elements andpresence of inclusions or contaminants

Epsilon 1 has optional small spot capability (1 mmspot size) with camera for easy positioning

Quantify inclusions and contaminants to determine their origin

SumXcore - Combined WD/ED XRF

Reduced measurement times with improved
precision and sensitivity

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EmpyreanAeris

The multi-purpose X-ray diffractometer

Phase analysis made simple

Empyrean is a multipurpose X-ray diffractometer for
determining the micro-structural characteristics of metal
powders and their fabricated components, including;Empyrean features a MultiCore Optics system thatenables a large variety of different measurements to be
performed automatically without manual intervention.

Aeris’ low cost of ownership delivers maximum returnon investment since it has limited infrastructure
requirements.

• phase composition

Empyrean has the unique ability to measure a variety ofsample types including powders, thin films, nanomaterials
and solid objects, over a wide range of temperatures.

Aeris is a user-friendly bench-top X-ray diffractometerthat provides fast, reliable and accurate phase
identification and quantification of your metal powders.
Aeris makes X-ray diffraction simple and accessible toeveryone. Aeris is also the first X-ray diffractometer to be
fully automatable and can be easily incorporated into a
relevant process.
The unique touch screen user interface lets you proceed
effortlessly through the measurement process andresults can also be analyzed in the HighScore software
to provide a wealth of crystallographic information.

Aeris is also the first benchtop to be fully automatable
and can be easily incorporated into a relevant process.

• crystallite size
• texture (crystallite orientation)• residual stress/strain
These characteristics can affect properties such as
hardness, strength and fatigue life, and are influenced
by thermal and mechanical processes such as
atomization, laser melting and powder pressing.

It has an unrivaled collection of sample stages andoptical components, including a tensile stage forsample analysis under stress, that can be easilyinterchanged to allow a wide range of diffraction,
scattering and imaging applications, including
computed tomography, to be performed.

For example, it has a small footprint and does not requirecompressed air or water cooling. It also has a much lower
power consumption compared to floor standing systems
and its X-ray tube has a virtually unlimited lifetime.

“Great machine that produces
accurate, high-resolution
and reproducible results ina short amount of time.”“Very reliable and modular system! I
love that I can quickly change thesystem from one mode to the otherto provide support to a number ofdifferent ongoing research projects.”

Charles Liu

SEMx Incorporated

David Tavakoli

Georgia Tech

FeaturesBenefits

MultiCore optics (iCore and dCore)

Automates measurements including multiple measurement
geometries to maximize instrument utilization and obtaina more complete understanding of your materials

Pre-aligned fast interchangeable X-ray modules (PreFIX)

Enables the diffractometer to be reconfigured in a few minutes
without module re-alignment, saving time and effort

Wide range of sample types

Can measure all sample types - from powders to thin films, fromnanomaterials to solid objects - even during tensile testing

Full suite of configurable modules andmeasurements including a tensile stage

Provides access to a wide range of diffraction, scatteringand imaging applications on a single platform

A range of non-ambient chambers for analysis
at temperatures ranging from -260ºC to 2000ºC
and under different atmospheric conditions

Study the effect of temperature, pressure, gas atmosphereand mechanical stress on phase transformation,
chemical reactions, recrystallization, etc.

HighScore/HighScore Plus Software

Provides comprehensive phase identification, profile fitting,Rietveld, crystallographic and extended cluster analysis

FeaturesBenefits

Simple touch-screen user interface

Intuitive operation that make measurements
quick and easy even for the novice

Minimal infrastructure requirements

No cooling water, no chiller, no compressed air - the only
thing you need is a single-phase power socket

HighScore/HighScore Plus Software

Provides comprehensive phase identification, profile fitting,Rietveld, crystallographic and extended cluster analysis

Powerful search-match algorithm for
multiple reference databases

Optimizes search criteria across a wide range of reference databases
making it easier to identify minor phases in the diffractogram

Automatable bench-top that can connect to a belt

Automate a process or perform high-throughput analysis

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17

Sample preparation equipment

Real-time particle sizing

What is fusion and why should I use it in my laboratory?

A watchful eye to optimize your process

Fusion is a sample preparation method developed in the
mid 50s. It involves dissolving a fully oxidized sample(at high temperature) in a suitable solvent (a flux) in aplatinum, zirconium or graphite crucible. The melted
mixture is agitated and poured into a mold to create aglass disk for XRF analysis. It can also be poured into abeaker to create a solution for AA or ICP analysis.

Manufacturing high quality metal powders economicallydemands exemplary process control. Establishedin-line and on-line particle sizing technologies provide
continuous process monitoring and a data stream that
supports complete process automation. Such technology
therefore makes it easier to make highly consistentproducts to a tight particle size specification at thelowest possible variable cost.

This universal technique has numerous benefits when
you compare it with other sample preparation methods
such as pressed pellets or acid digestion. One of themain advantages of using fusion in the preparationof metals is that the technique is not affected bymineralogical or particle size effects, thus enhancing the
precision and accuracy of XRF results.

Why should I use fusion in my lab?

At the same time, continuous particle sizing has a role toplay in managing the re-use of high-value AM powders,a critical issue for economic viability. With a proven trackrecord and strong reliability, in-line and on-line particle
sizing technology holds considerable value for metal
powder manufacturers establishing robust supply chainsfor the PM industry, and for AM users looking to optimize
their powder management processes.

Atomization tower

This universal technique has numerous benefits when you compare it with other sample preparation
methods such as pressed pellets or acid digestion
FusionPressed pellets

Affected by mineralogy

No

Yes

Affected by particle size

No

Yes

Desirable size of powder (microns)

50 - 100 (Easy)

5 - 30 (Difficult)Accuracy

≤1%

≤10%

Easy clibration with synthetic standards

Yes

No

Application of matrix correction

Yes

No

Product
cycloneCoolerTransfer
Water cooling

LeNeo fusion instrument preparesglass disks for XRF analysis as well
as borate and peroxide solutions
for AA and ICP analysis. This
automatic electric instrument has
one fusion position and is easy touse. It guarantees safety for theoperator as well as superior analytical
performances in the laboratory.

TheOx Advanced fusion instrument
has been designed by our experts
to suit our customers’ ever-changing
needs. This instrument is powered byelectricity and has six fusion positions.
It is used to prepare glass disks for
XRF analysis as well as borate andperoxide solutions for AA and ICP
analysis. Its extra features enhance
analytical performance and safety,
benefiting users at all levels.

The Eagon 2 is a fully automatic
fusion instrument that prepares glass
disks for XRF analysis. Its innovative
patented design ensures performance,
operator safety and ease of use. The
Eagon 2 instrument makes fusion andthe consequent benefits for accurate
XRF analysis easily achievable.

Sieving unit

Laser diffraction (Insitec)
Spacial filter velocimetry (Parsum)

Real-time measurement system makes it possible toinstantly observe the effect of decreasing the speedof rotation of the atomizing disk and the time taken
for the process to re-establish a steady state. (Green
Dv10, blue Dv50, orange Dv90, red is transmission).

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19

Insitec

ParsumRobust, reliable, real-time particle sizing for process control

Real-time size measurements for screening applications

Insitec analyzers are on-line laser diffraction systems thatprovide continuous particle size analysis, for efficient,cost-effective monitoring and control of industrial
process streams including dry powders, slurries andsprays in the size range 0.1 μm to 2.5 mm.

The Parsum probe measures particle size distributionsand velocities of solid particles in gas streams using apatented spatial filtering velocimetry technique. It hasa size range of 50 μm to 6 mm and is widely used formonitoring and optimization of screening operations.
Real-time particle distribution data enables the user toreduce variability during processing and detect screen
breakages by monitoring for oversized particles.

Insitec provides real-time particle size distribution forautomatic ‘closed loop’ process control, enabling theoperator to optimize and control processes such as spraydrying, atomization, milling and screening, and react inreal-time to production fluctuations.
Malvern Link™ II software interface, enables full
integration with your plant control system and unlocks
the potential value of timely particle size measurement.
The dedicated analysis software, automation anddata reporting can be customized to meet individual
requirements.

The probe contains an array of light sensitive detectors
which are illuminated by a laser. This array can detect
single particles as they pass through the laser beam
within the probe measurement zone. The shadow
produced by each particle can be used to calculate theparticle velocity and its chord length (particle size).
The detector signals are sampled very rapidly (up to
10,000 particles per second) and particle size distribution
data is continuously updated during operation to produce
a real time particle size trend. This provides direct insight
into the performance of the process without the need forsample extraction.

“For us, the Insitec is an essential tool
for optimizing the performance of thefinishing mills and it is of great value
to the production teams. It provides
continuous particle size data for thematerial exiting the mills, so that theoperators can react quickly and confidently
when making control decisions.”

Michel Berger
HolcimFeaturesBenefits

FeaturesBenefits

Measure particles in the size range 0.1 µm – 2500 µm.

Enable accurate measurement of metal powder from a range of processes

Optical head and sample path certified to
Pressure Shock Resistance of 11bar(a) (PSR11)

Withstands extreme conditions of metal powder production

Real-time measurement of particles in the size
range 50 µm to 6 mm during processing

Continuous and uninterrupted monitoring of processes
such as sieving, pneumatic transport and mixing

Measure up to 20,000 particles in real-time

Ceramic linings protect critical, highvelocity areas of the sample pathway andpurging protects windows from dust

Maintenance requirements are minimal

Fast and statistically representative data for confident
decision making and optimum process control

Wide range of accessories, such as inline
dispersers and cleaning cells

Provides a so-called “process interface” for adapting themeasurement probe to different conditions within the process.

Provides continuous particle size data

Operators can react quickly and confidently
when making control decisions

Range of different probes for various
processes and environments

Make real-time measurements inside mixing vessels, undersieve-decks and during conveying, even in ATEX zones

Meets all the recommendations for ISO13320

Guarantees quality and compliance

IPP measuring software

Measures representative sample volume

Statistical reliability for process control

Flexible and adaptable system of programmes and interfaces thatcan control 4 probes simultaneously and gives real-time updatesof particle size distributions and sieve fractions/throughputs

Control system integration options –OPC, Modbus, Profibus, wired IO

Ease of reporting

Integrated software interface for plant automation

Deliver results in real-time to your control room and allow automation ofroutine tasks such as cleaning, maintenance and background checks

Malvern Panalytical is a global leader in the analytics ofmaterial and life sciences. We unleash the power of smallthings to make big things happen for our customers.
Our vision is to make the world cleaner, healthier, andmore productive.
We partner with our customers to make their solutions
possible through the power of precision measurements,
our expertise, trusted data, and insights.

Service & Support
Malvern Panalytical provides the global training, service
and support you need to continuously drive youranalytical processes at the highest level. We help you
increase the return on your investment, and ensure thatas your analytical requirements grow, we’re there to
support you.
Our worldwide team of specialists adds value to yourbusiness processes by ensuring applications expertise,
rapid response, and maximum instrument uptime.
• Proactive local and remote support

Our people are partners in discovery. We collaborate
with our customers and with each other to discover new
possibilities and achieve breakthroughs.

• Full and flexible range of service agreements

Our culture is a healthy, high-performance culture shapedby our values: Own it, Aim High and Be True.

• e-Learning training courses and web seminars

We’re committed to Net Zero in our own operations by
2030 and in our total value chain by 2040.
With over 2300 employees across the globe, we are partof Spectris plc, the world-leading precision measurement
group.

• Compliance and validation support• Onsite or classroom-based training courses• Digital services, including MyStore and My Customer
Support Portal• Sample analysis, method development, andapplications consultancy

Malvern Panalytical. We’re big on small™

Malvern Panalyticalwww.malvernpanalytical.com

Grovewood Road, Malvern,
Worcestershire, WR14 1XZ,
United Kingdom

Lelyweg 1,7602 EA Almelo,
The Netherlands

Tel. +44 1684 892456
Fax. +44 1684 892789

Tel. +31 546 534 444
Fax. +31 546 534 598

Disclaimer: Although diligent care has been used to ensure that the information in this material is accurate, nothing herein can be construed to imply any representation or warranty as to the accuracy, correctness or completenessof this information and we shall not be liable for errors contained herein or for damages in connection with the use of this material. Malvern Panalytical reserves the right to change the content in this material at any time without notice.
Copyright: © 2024 Malvern Panalytical. This publication or any portion thereof may not be copied or transmitted without our express written permission. PN14306

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