Laser powder bed fusion (PBF-LB) is a technology growing in popularity as it allows for freedom in component design, while a significant range of materials can be manufactured using this method. One of the major considerations when using this manufacturing technique is the quality of powder feedstock, given the range of powder production processes and suppliers for this feedstock. AlSi7Mg is an aluminium alloy commonly used in PBF-LB, and so this work compares the properties of two different powder batches and the influences they have on mechanical properties. These powders were sourced from the same supplier; however, one batch was gas atomised while the other was plasma atomised. Powder properties were compared using powder size, flowability, and chemistry measurements. Mechanical performance was analysed through tensile, hardness, Charpy, and fatigue testing. The findings of these investigations indicate that great care needs to be taken when comparing otherwise identical components manufactured from different powder batches, even when these powder batches are sourced from the same supplier.

Keywords: PBF-LB; AlSi7Mg; powder characterisation; powder quality