A mechanically stirred fluid-bed rheometer (msFBR) was used to study the rheology of powders aerated below the fluidisation threshold. Glass ballotini (group B) and silica powders (group A) with different fine contents were tested. The torque necessary to rotate an impeller immersed in a bed of aerated powders was measured for different impeller depths and aeration rates. A model was developed: (a) to estimate the state of stress at the impeller depth, following Janssen's approach for the evaluation of stresses in silos, and (b) to evaluate the torque, with the hypothesis that it is determined by the powder shear on a flat cylinder surface around the impeller. The model uses some powder properties, such as the dynamic and the wall yield loci of the powder used, which were estimated with a Peschl shear cell modified for small loads. The reasonable prediction of the torque at impeller depth larger than 3 cm provided by the model supports the hypothesis that the torque is defined by the plastic deformation of powders and can be explained within a simple Mohr-Coulomb approach to powder flow. The passive stress distribution that appears to set up during the shearing experiments leaves open some fundamental questions regarding the limiting conditions determining such behaviour. As in previous experiments found in the literature, aeration does not affect the rheology of powders but modifies the stress distribution within the bed. The content of fines turns out to be a key factor in the determination of powder rheology as measured both with the shear cell and with the fluid-bed rheometer. (c) 2006 Elsevier Ltd. All rights reserved.