What Is Powder Testing?
Powder testing evaluates the physical, chemical, and surface properties of fine particulate materials like powders. It accounts for the unique physical characteristics that are present in powders to better understand their behavior and make informed decisions. Powders are very unique in that they are technically solid, but given their size, consistency, and interaction between particulates, they often behave like liquids with their moisture content, stability, and flowability. Covalent’s particle characterization services help take the complexities of a powder and transform them into insight.
Why Invest in Powder Testing?
When powder is involved in your manufacturing or working process, powder testing techniques help with:
- Performance Measurement: To verify powder flow, compaction, and stability.
- Processing and Logistics: To improve handling, storage, and manufacturability.
- Quality Control: To identify contamination, variability, or degradation.
- Material Selection: To select powders and formulations that match product requirements.
- Production Scale: Consistency: To confirm batch-to-batch uniformity during production.
When Should Powder Testing Be Performed?
- Research and Development: To optimize particle engineering and formulation.
- Production: To monitor consistency and prevent production delays or variability.
- Pre-launch: To ensure material quality for market readiness and launch.
- Failure Analysis: Relevant if you observe clumping, segregation, or powder-related field failures.
Industries That Use Powder Testing
Powder testing is used in various industries for its importance in understanding material function and behavior. Our powder analysis laboratory specializes in helping:
Pharmaceuticals & Biotech
For tablet formulation, controlled-release drugs, and inhalable drugs.
Energy & Batteries
Used for electrode powders and conductive additives.
Catalysts & Chemicals
To optimize or maximize surface area for reactivity.
Additive Manufacturing Powder Testing (3D Printing)
To transform metal or plastic/polymer powder into printed solids, evaluating flowability, particle size, and printer consistency.
Food & Agriculture
For consistency of flavorings, supplements, fertilizers, and stabilizers.
Key Differentiators
Advantages
- Tailored to the unique physical properties of a powder, often straddling the properties of solids and liquids.
- Evaluates particle size, shape, and density.
- Versatility: If the material can be powdered, techniques can evaluate it. Metals, ceramics, polymers, composites, and more can be measured.
- Scalability: It is relatively easy to apply techniques on a small scale in a lab or at full production volume in quality control programs and testing.
Limitations
- Powder testing may destroy, consume, or contaminate the sample.
- Powders are subject to environmental variation and therefore need tightly controlled variables that affect powder performance, such as moisture and humidity.
- The results may be complex to interpret, but Covalent offers experience in interpreting results.
What Properties Are Measured in Powder Testing?
Through mechanical or chemical methodologies, we can compact, flow, heat, illuminate, or disperse a powder to observe its properties such as particle size distribution, surface morphology, flow rate, surface chemistry, and more. We use powder testing to:
- Evaluate whether a powder is suitable for its intended application, including manufacturing, storage, and eventual performance.
- Understand the particle size and shape, both of which impact the powder behavior.
- Flowability.
- Surface area and porosity.
- Moisture content.
- Chemical composition or trace contamination.
Types of Powder Testing
- Flowability Testing: Measures the flow of a powder, clumping, and inconsistencies.
- Particle Size and Shape Analysis: Measures the size and shape of powder particles, which affects the surface area, dissolution rate, flowability, and density.
- Density and Porosity Testing: Looks at how tightly packed or porous the particles are, which impacts material strength, stability, and performance.
- Moisture and Hygroscopicity Testing: Considers how much water is present in a powder and how easily it absorbs moisture, which affects flow, shelf life, reactivity, and stability.
- Surface Area and Reactivity: Measures the specific surface area of powder particles. Higher surface areas generally increase reactivity and can enhance dissolution or adsorption behavior, depending on the material.
- Mechanical Property Testing: Tests a powder’s response to compression, stress, or shear forces.
- Electrostatic and Magnetic Testing: Measures the powder’s accumulation of static charges and its response to magnetic fields.
- Thermal Analysis: Looks at the powder’s response to changes in temperature.
How Are Results Tracked and Reported?
At Covalent, we support the project from the first email. We will help you choose the right method, advise on the best way to ship the samples, and discuss the scope of work with you. In some cases, you can request a live session in the powder analysis laboratory or remotely. Our reports include:
- High-resolution images, spectra, tables, and figures.
- Quantified measurements with precision calibration, if required.
- Raw data upon request.
- Interpretation aligned to goals.
- Information about used equipment and methods.
Our engineers will be happy to follow up on any questions or concerns you may have.
Why Choose Covalent for Powder Analysis Services?
Covalent is the answer for all powder analysis testing needs. Our cutting-edge powder analysis laboratory is fully equipped with comprehensive tools, allowing for the aggregation of input from multiple tests. Our expert and highly qualified team uses various methods to piece together the answers you need. We also offer live sessions where you can collaborate with our expert team during the measurements.
Frequently Asked Questions
What is the typical turnaround time for powder characterization services tests like particle size analysis?
We support 5 days TAT, however iIt depends on the scope of your project. We offer expedited testing if a quicker turnaround time is essential.Give us a call today to discuss your specific needs.
Can you test recycled or reused metal powder to verify if they are still within specification for additive manufacturing powder testing?
Yes, we can verify reused powders to confirm they meet performance specifications.
Why is it important to measure both particle size and particle shape? What do they tell me differently about my powder?
Measuring both particle size and particle shape is important because they describe different aspects of the powder that independently affect its behavior. Particle size determines surface area, dissolution rate, flowability, packing density, and how powders spread or compact. Particle shape (roundness, aspect ratio, angularity) affects flow behavior, cohesion, packing efficiency, and how particles interact mechanically
Beyond the data report, do you offer consulting to help us understand how our powder's properties will affect the performance of our final product?
Yes. We offer consultations with experts in the field who will explain the data and results and answer all your questions.
Related Techniques for Powder Testing
- Laser Diffraction Particle Size Analysis: Measures particle size distributions rapidly and reproducibly for suspensions or powders. Supports QC, formulation tuning, and process control across wide size ranges.
- Powder Rheometry: Quantifies powder flowability, cohesion, and shear properties under controlled stresses. Predicts handling, dosing, and processing performance for manufacturing and additive workflows.
- Porosimetry: Determines surface area, pore size distribution, and porosity. Optimizes adsorption, catalytic activity, permeability, and packing for powders and porous materials.
- TGA and DSC: Measures mass change and heat flow versus temperature. Identifies composition, thermal stability, phase transitions, and reactions to guide processing and formulation.
- SEM: High-resolution imaging of powder morphology, size, and surface features. Identifies agglomeration, shape, and defects to support quality control and process optimization.
Laser Diffraction Particle Size Analysis (LD-PSA)
Analyzes particle sizes by measuring light scattering. Explore
Differential Scanning Calorimetry (DSC)
Quantifies heat flow for material optimization. Explore
Scanning Electron Microscopy (SEM)
Images surface topography and composition with electrons. Explore
Thermogravimetric Analysis (TGA)
Measures material mass changes with temperature or time. Explore
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