A well-established characterization method is required in powder bed fusion (PBF) metal additive manufacturing, where metal powder is used. The characterization methods from the traditional powder metallurgy process are still being used. However, it is necessary to develop advanced methods of property evaluation with the advances in additive manufacturing technology. In this article, the characterization methods of powders for metal PBF are reviewed, and the recent research trends are introduced. Standardization status and specifications for metal powder for the PBF process which published by the ISO, ASTM, and MPIF are also covered. The establishment of powder characterization methods are expected to contribute to the metal powder industry and the advancement of additive manufacturing technology through the creation of related databases.

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• Enhanced flow properties of SiO 2 nanoparticles coated low-cost hydrogenation-dehydrogenation Ti-6Al-4V powder for powder bed fusion process
  Ukju Gim, Sehun Kim, Tae hu Kang, Jongik Lee, Sanghee Jeong, Jimin Han, Bin Lee
  Powder Metallurgy.2025; 68(2): 95.     CrossRef
• SiO 2 nanoparticle-coated Ti-6Al-4V spherical powder for powder bed fusion additive manufacturing process
  Jongik Lee, Taehoo Kang, Ukju Gim, Sehun Kim, Sanghee Jung, Jimin Han, Bin Lee
  Powder Metallurgy.2025;[Epub]     CrossRef
• Effect of Support Structure on Residual Stress Distribution in Ti-6Al-4V Alloy Fabricated by Laser Powder Bed Fusion
  Seungyeon Lee, Haeum Park, Min Jae Baek, Dong Jun Lee, Jae Wung Bae, Ji-Hun Yu, Jeong Min Park
  Journal of Powder Materials.2025; 32(3): 244.     CrossRef
• A Study on Fabrication of PCD Endmill Holder using PBF Additive Manufacturing Technology
  Min-Woo Sa, Ho-Min Son, Kyung-Hwan Park, Sang-Geun Lee, Dae-Ho Shin, Dong-Gyu Kim
  Journal of the Korean Society of Manufacturing Process Engineers.2024; 23(6): 124.     CrossRef
• Rheological Characteristic Analysis Methods and Tests of Metal Powders for PBF Additive Manufacturing
  Wan-Sik Woo, Ho-Jin Lee
  Journal of the Korean Society of Manufacturing Process Engineers.2023; 22(10): 1.     CrossRef
• Residual Stress Analysis of Additive Manufactured A356.2 Aluminum Alloys using X-Ray Diffraction Methods
  SangCheol Park, InYeong Kim, Young Il Kim, Dae-Kyeom Kim, Soong Ju Oh, Kee-Ahn Lee, Bin Lee
  Korean Journal of Metals and Materials.2023; 61(7): 534.     CrossRef
• Enhancing spreadability of hydrogenation-dehydrogenation titanium powder and novel method to characterize powder spreadability for powder bed fusion additive manufacturing
  Young Il Kim, Dae-Kyeom Kim, InYeong Kim, Sang Cheol Park, Dongju Lee, Bin Lee
  Materials & Design.2022; 223: 111247.     CrossRef

In this paper, a durability study is presented to enhance the mechanical properties of an Fe-Si-Al powderbased magnetic core, through the addition of graphite. The compressive properties of Fe-Si-Al-graphite powder mixtures are explored using discrete element method (DEM), and a powder compaction experiment is performed under identical conditions to verify the reliability of the DEM analysis. Important parameters for powder compaction of Fe-Si-Algraphite powder mixtures are identified. The compressibility of the powders is observed to increase as the amount of graphite mixture increases and as the size of the graphite powders decreases. In addition, the compaction properties of the Fe-Si-Al-graphite powder mixtures are further explored by analyzing the transmissibility of stress between the top and bottom punches as well as the distribution of the compressive force. The application of graphite powders is confirmed to result in improved stress transmission and compressive force distribution, by 24% and 51%, respectively.

In this study, a method to remove residual powder on a multi-layered graphene and a new approach to transfer multi-layered graphene at once are studied. A graphene one-step transfer (GOST) method is conducted to minimize the residual powder comparison with a layer-by-layer transfer. Furthermore, a residual powder removing process is investigated to remove residual powder at the top of a multi-layered graphene. After residual powder is removed, the sheet resistance of graphene is decreased from 393 to 340 Ohm/sq in a four-layered graphene. In addition, transmittance slightly increases after residual powder is removed from the top of the multi-layered graphene. Optical and atomic-force microscopy images are used to analyze the graphene surface, and the Ra value is reduced from 5.2 to 3.7 nm following residual powder removal. Therefore, GOST and residual powder removal resolve the limited application of graphene electrodes due to residual powder.

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• Partially Dry-Transferred Graphene Electrode with Zinc Oxide Nanopowder and Its Application on Organic Solar Cells
  Yeongsu Jo, Chae Young Woo, Soon Kyu Hong, Hyung Woo Lee
  Journal of Korean Powder Metallurgy Institute.2020; 27(4): 305.     CrossRef

In this study, two types of SKD61 tool-steel samples are built by a selective laser melting (SLM) process using the different laser scan speeds. The characteristics of two kinds of SKD61 tool-steel powders used in the SLM process are evaluated. Commercial SKD61 tool-steel power has a flowability of 16.68 sec/50 g and its Hausner ratio is calculated to be 1.25 by apparent and tapped density. Also, the fabricated SKD61 tool steel powder fabricated by a gas atomization process has a flowability of 21.3 sec/50 g and its Hausner ratio is calculated to be 1.18. Therefore, we confirmed that the two powders used in this study have excellent flowability. Samples are fabricated to measure mechanical properties. The highest densities of the SKD61 tool-steel samples, fabricated under the same conditions, are 7.734 g/cm³ (using commercial SKD61 powder) and 7.652 g/cm³ (using fabricated SKD61 powder), measured with Archimedes method. Hardness is measured by Rockwell hardness testing equipment 5 times and the highest hardnesses of the samples are 54.56 HRC (commercial powder) and 52.62 HRC (fabricated powder). Also, the measured tensile strengths are approximately 1,721 MPa (commercial SKD61 powder) and 1,552 MPa (fabricated SKD61 powder), respectively.

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• Microstructural effects on the tensile and fracture behavior of selective laser melted H13 tool steel under varying conditions
  Jungsub Lee, Jungho Choe, Junhyeok Park, Ji-Hun Yu, Sangshik Kim, Im Doo Jung, Hyokyung Sung
  Materials Characterization.2019; 155: 109817.     CrossRef

The friction characteristics of Al-Fe alloy powders are investigated in order to develop an eco-friendly friction material to replace Cu fiber, a constituent of brake-pad friction materials. Irregularly shaped Al-Fe alloy powders, prepared by gas atomization, are more uniformly dispersed than conventional Cu fiber on the brake pad matrix. The wear rate of the friction material using Al-8Fe alloy powder is lower than that of the Cu fiber material. The change in friction coefficient according to the friction lap times is 7.2% for the Cu fiber, but within 3.8% for the Al-Fe alloy material, which also shows excellent judder characteristics. The Al-Fe alloy powders are uniformly distributed in the brake pad matrix and oxide films of Al and Fe are homogeneously formed at the friction interface between the disc and pad, thus exhibiting excellent friction and lubrication characteristics. The brake pad containing Al-Fe powders avoids contamination by Cu dust, which is generated during braking, by replacing the Cu fiber while maintaining the friction and lubrication performance.

Titanium alloys have high specific strength, excellent corrosion and wear resistance, as well as high heatresistant strength compared to conventional steel materials. As intermetallic compounds based on Ti, TiAl alloys are becoming increasingly popular in the aerospace field because these alloys have low density and high creep properties. In spite of those advantages, the low ductility at room temperature and difficult machining performance of TiAl and Ti3Al materials has limited their potential applications. Titanium powder can be used in such cases for weight and cost reduction. Herein, pre-forms of Ti-Al-xMn powder alloys are fabricated by compression forming. In this process, Ti powder is added to Al and Mn powders and compressed, and the resulting mixture is subjected to various sintering temperature and holding times. The density of the powder-sintered specimens is measured and evaluated by correlation with phase formation, Mn addition, Kirkendall void, etc. Strong Al-Mn reactions can restrain Kirkendall void formation in Ti-Al-xMn powder alloys and result in increased density of the powder alloys. The effect of Al-Mn reactions and microstructural changes as well as Mn addition on the high-temperature compression properties are also analyzed for the Ti-Al-xMn powder alloys.

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• Lattice Deformation and Improvement Oxidation Resistance of Ti-6Al-4V Alloy Powders Prepared by Hydrogen Added Argon Heat Treatment
  Gye-Hoon Cho, Jung-Min Oh, Jae-Won Lim
  Journal of Korean Powder Metallurgy Institute.2019; 26(2): 126.     CrossRef
• Effect of post heat treatment on fatigue properties of EBM 3D-printed Ti-6Al-4V alloy
  Young-Sin Choi, Ji-Hoon Jang, Gun-Hee Kim, Chang-Woo Lee, Hwi-Jun Kim, Dong-Geun Lee
  Journal of Korean Powder Metallurgy Institute.2018; 25(4): 340.     CrossRef

In this study, H13 tool steel sculptures are built by a metal 3D printing process at various laser scan speeds. The properties of commercial H13 tool steel powders are confirmed for the metal 3D printing process used: powder bed fusion (PBF), which is a selective laser melting (SLM) process. Commercial H13 powder has an excellent flowability of 16.68 s/50 g with a Hausner ratio of 1.25 and a density of 7.68 g/cm³. The sculptures are built with dimensions of 10 × 10 × 10 mm3 in size using commercial H13 tool steel powder. The density measured by the Archimedes method is 7.64 g/cm³, similar to the powder density of 7.68 g/cm³. The hardness is measured by Rockwell hardness equipment 5 times to obtain a mean value of 54.28 HRC. The optimum process conditions in order to build the sculptures are a laser power of 90 W, a layer thickness of 25 μm, an overlap of 30%, and a laser scan speed of 200 mm/s.

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• Spheroidization of Enamel Powders by Radio Frequency Plasma Treatment and Application to Additive Manufacturing
  Ki-Bong Kim, Dong-Yeol Yang, Yong-Jin Kim, Jungho Choe, Ji-Na Kwak, Woo-Hyung Jung
  Journal of Korean Powder Metallurgy Institute.2020; 27(5): 388.     CrossRef
• Microstructural effects on the tensile and fracture behavior of selective laser melted H13 tool steel under varying conditions
  Jungsub Lee, Jungho Choe, Junhyeok Park, Ji-Hun Yu, Sangshik Kim, Im Doo Jung, Hyokyung Sung
  Materials Characterization.2019; 155: 109817.     CrossRef
• Nano-mechanical Behavior of H13 Tool Steel Fabricated by a Selective Laser Melting Method
  Van Luong Nguyen, Eun-ah Kim, Jaecheol Yun, Jungho Choe, Dong-yeol Yang, Hak-sung Lee, Chang-woo Lee, Ji-Hun Yu
  Metallurgical and Materials Transactions A.2019; 50(2): 523.     CrossRef
• Correlation between Microstructure and Mechanical Properties of the Additive Manufactured H13 Tool Steel
  Woojin An, Junhyeok Park, Jungsub Lee, Jungho Choe, Im Doo Jung, Ji-Hun Yu, Sangshik Kim, Hyokyung Sung
  Korean Journal of Materials Research.2018; 28(11): 663.     CrossRef
• Evaluation of Strain-Rate Sensitivity of Selective Laser Melted H13 Tool Steel Using Nanoindentation Tests
  Van Luong Nguyen, Eun-ah Kim, Seok-Rok Lee, Jaecheol Yun, Jungho Choe, Dong-yeol Yang, Hak-sung Lee, Chang-woo Lee, Ji-Hun Yu
  Metals.2018; 8(8): 589.     CrossRef
• Comparison of Nano-Mechanical Behavior between Selective Laser Melted SKD61 and H13 Tool Steels
  Jaecheol Yun, Van Luong Nguyen, Jungho Choe, Dong-Yeol Yang, Hak-Sung Lee, Sangsun Yang, Ji-Hun Yu
  Metals.2018; 8(12): 1032.     CrossRef
• A study about sculpture characteristic of SKD61 tool steel fabricated by selective laser melting(SLM) process
  Jaecheol Yun, Jungho Choe, Ki-Bong Kim, Sangsun Yang, Dong-Yeol Yang, Yong-Jin Kim, Chang-Woo Lee, Chang-Woo Lee
  Journal of Korean Powder Metallurgy Institute.2018; 25(2): 137.     CrossRef