Digital Twin Approach For Powder Lifecycle Management: Investigation Of Aluminum Powder Aging In L-PBF Processes

Authors:

Peter Lindecke (amsight GmbH, Germany)
Daniel Rommel (Colibrium Additive, a GE Aerospace company, Germany)

Abstract:

This study investigates powder management and associated mechanical properties in the additive manufacturing (AM) of aluminum using Laser Powder Bed Fusion (L-PBF). The focus is on the development of a novel, holistic data management system for digital capture and analysis of the complete powder lifecycle. For the first time, the system enables comprehensive documentation of all quality-relevant powder parameters such as particle size distribution, chemical composition, and flow behavior in conjunction with process data and resulting component properties. In a long-term study, the aging behavior of aluminum powder was systematically investigated over multiple reuse cycles. The results demonstrate that optimized powder reconditioning can be achieved while simultaneously ensuring component quality. The developed data management system thus forms the foundation for cost-efficient and sustainable powder utilization in the L-PBF process while meeting regulatory requirements.

DOI:

https://doi.org/10.59499/EP256767166