Abstract
Laser powder bed fusion (LPBF) is an outstanding additive manufacturing (AM) technology that can enable both complicated geometries and desired mechanical properties in high-value components. However, the process reliability and cost have been the obstacles to the extensive industrial adoptions of LPBF. This work aims to develop a powder recycling procedure to reduce production cost and minimize process uncertainties due to powder degradation. We used a recycle index (R) to reuse Ti-6Al-4V powder through 10 production cycles. Using this recycle index is more reasonable than simply replying on recycle numbers as it incorporates the powder usage history. A recycling procedure with simple virgin powder top-up can effectively mitigate powder degradation and maintain stable powder properties, chemical compositions, and tensile properties. The experimental finding points to a sustainable recycling strategy of Ti alloy powders with minimal material waste and without noticeable detriment to observed mechanical performance through LPBF production cycles.
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