Authors:
Caterina Iantaffi (European Space Agency, Netherlands)
Martina Meisnar (European Space Agency, Netherlands)
Jonathan Allen (Alloyed Ltd., United Kingdom)
Chantal Fowler (Science and Technology Facilities Council (STFC), United Kingdom)
Charlie Pearson (Alloyed Ltd., United Kingdom)
Rory Rose (Alloyed Ltd., United Kingdom)
Thomas Rohr (European Space Agency, Netherlands)
Abstract:
Powder reuse in laser powder bed fusion (LPBF) offers opportunities to reduce production costs and environmental impact; but may alter powder properties, potentially compromising part quality. The limited understanding of how powder degradation during reuse affects melt pool behaviour and part quality restricts its industrial adoption [1]. This study investigates the reuse of a single AlSi10Mg powder batch through a top-up approach in an industrial LPBF system (EOS M290) with a IPCM PRO sieving unit for recycling and storage. Powder was added and cycled to reach 8 reuse levels. Results indicate that with increased reuse levels, powder particle size distribution becomes finer and cohesivity decreases [2]. These improvements in powder properties, likely due to sieving and wear, may be responsible for the observed enhanced part density and reduced surface roughness. Microstructure and mechanical properties of printed parts at different reuse levels are also analysed and linked to powder property changes.
DOI:
https://doi.org/10.59499/EP256767045
