Multi-scale imaging of additively manufactured Al–Ta composites

Abstract The rapid advancement of metal additive manufacturing (AM) has driven the need for innovative feedstock materials, with nano- to micro-alloyed composite powders playing a pivotal role in the development of new materials. In aluminium alloys, alloying additives are introduced to eliminate hot cracking. Composite feedstock quality is therefore critical, as it influences the effectiveness of additives on the final part properties. The particle morphology, size distribution, and structural integrity of feedstock powders directly affect the density and mechanical performance of additively manufactured components. This study employs X-ray computed tomography (XCT) and scanning electron microscopy (SEM) for a comprehensive, quantitative evaluation of Al–Ta composite powders and their manufactured counterparts in the Laser Powder Bed Fusion (PBF-LB/M) process. The integration of XCT and SEM enables a detailed characterisation of powder features and their potential impact on microstructural integrity. Our findings demonstrate the capability of XCT as a non-destructive, high-resolution technique that complements SEM for precise volumetric analysis of powder morphology, structural homogeneity, and defect identification.