Abstract
Powder properties are vital to the realization of high-performance metallic components via laser powder bed fusion (LPBF). However, metallic powder recycled during LPBF exhibits out-of-specification properties, thus causing components subjected to LPBF to possess inferior tensile ductility. Hence, we devise a discharge plasma modification (DPM) method to heal out-of-specification Ti powder recycled during LPBF, which can be used to manufacture high-performance bulk Ti via LPBF. The hexagonal ω-phase, which is present during the LPBF of as-received Ti powder and is caused by low O contents and high laser pressures, reappears during the LPBF of recycled and DPMed Ti powders. Bulk Ti subjected to LPBF possesses excellent tensile strength and ductility that are comparable to those of metallic Ti processed via various methods. Our results provide an inexpensive method for sustainable recycling metallic powders and manufacturing high-performance metallic components using LPBF.
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