The thermal spray industry identified the need for repeatable and reproducible feedstock powder characterization methods, especially particle size distribution (PSD), for cost effective manufacturing of thermal barrier coatings. The PSD measurement by a laser light scattering method was identified as the technique most widely used in the industry. This technique offers high resolution, rapid measurements and ease of use. A round robin study by nine laboratories using different models of a commercial light scattering instrument has been completed as the first step towards the development of a Standard Reference Material (SRM) for the calibration of light scattering instrument. Other measurement techniques were also employed for additional comparison. The PSD measurements employing light scattering techniques evidenced some method dependence, despite the use of identical sample preparation procedures. The round robin results will serve as reference values for the development of the SRM.

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