On the structural integrity and fatigue performance of additively manufactured Ti-6Al-4V parts processed using mechanically recycled powders

Abstract

In light of the steadily increasing importance of resource efficiency, powder recycling represents one of the major prospects in additive manufacturing. The present study focuses on Ti6Al4V parts manufactured by electron beam-based powder bed fusion using blends of virgin and recycled powder. The latter powder was gained by mechanical comminution of support structures and, thus, addresses a novel topic beyond the well-known reuse of un-melted powder. Microstructure analysis is conducted by scanning electron microscopy and micro-computed tomography, mechanical properties are analyzed by quasi-static tensile and fatigue tests. Thereby, the applicability of recycled powder is assessed, eventually revealing that mechanically recycled powder can be qualified to partially substitute virgin powder in powder bed additive manufacturing.