Abstract
Titanium alloy powder used for laser-based powder bed fusion (L-PBF) process is costly. One of the solutions is the inclusion of a powder recycling strategy, allowing unused or exposed powder particles to be recuperated post manufacture, replenished and used for future builds. However, during a L-PBF process, powder particles are exposed to high levels of concentrated energy from the laser. Particularly those in close proximity to the melt pool, leading to the formation of spatter and agglomerated particles. These particles can settle onto the powder bed, which can then influence the particle size distribution and layer uniformity. This study analysed extra-low interstitial (ELI) Ti6Al4V (Grade 23) powder when subjected to nine recycle iterations, tracking powder property variation across the successive recycling stages. Characterisation included chemical composition focusing upon O, N, and H content, particle size distribution, morphology and tapped and bulk densities. On review of the compositional analysis, the oxygen content exceeded the 0.13% limit for the ELI grade after 8 recycles, resulting in the degradation from Grade 23 level.
Highlights
The production costs associated with powder feedstock manufacturing processes are high.A practical way to reduce costs associated with the use of powder feedstock is to recycle powder from previous part builds
Of the of the powder within the build volume is utilised [1]. Within this additive manufacturing (AM) process, the powder is consolidated into the final part and the remainder is available for reuse
Addition, the associated with the process, on-going challenges remain in relation to the powder material
Summary
The production costs associated with powder feedstock manufacturing processes are high. The fabrication process uses a high energy laser beam to selectively melt particles that have been deposited onto the powder bed by a recoater density laser beam blade to selectively thatand have beenheight deposited onto the powder bed by blade. Of the virgin powder properties is lower associated the production process. The condition of the virgin powder properties is associated thespherical production process. The powders used in L-PBF have many stringent requirements flowability, size distribution (PSD), processes and composition, among others.technical. Addition, the associated with the process, on-going challenges remain in relation to the powder material. The topped-up is reintroduced back into the L-PBF the L-PBF fabrication This is repeated untilpowder the quantity of virgin powder available for machine for fabrication.
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