A comprehensive characterization of virgin and recycled 316L powders during laser powder bed fusion

Lu, Chenyang; Zhang, Ruihua; Xiao, Mi; Wei, Xiaohong; Yin, Yan Sheng; Qu, Yuebo; Li, Hui; Liu, Pengyu; Qiu, Xiaopan; Guo, Tao

doi:10.1016/j.jmrt.2022.03.125

Cited by 11 publications

(10 citation statements)

References 47 publications

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“…In this scenario, any changes as a result of powder recycling would be expected to be exacerbated as no virgin powder is added to dilute the effects of powder recycling. This approach of no topping up of the powder batch with virgin powder was also adopted by Lu et al, [ 21 ] which also resulted in powder coarsening with recycling. After 30 recycles the D 10 value increased 26% from 15.54 to 19.60 μm, while D 50 and D 90 also increased by 18% and 15%, respectively.…”

Section: Changes To Powder Properties As a Results Of Recyclingmentioning

confidence: 99%

“…Lu et al also observed a progression with the coarsening of the metal powder from 10 recycles to 30 recycles, as shown in Figure . [ 21 ]…”

Section: Changes To Powder Properties As a Results Of Recyclingmentioning

confidence: 99%

“…The PSD of virgin 316L powder compared to the same powder that has been recycled 10 and 30 times. [ 21 ] . The coarsening of the powder gradually shifts the peak of the PSD to the right.…”

Section: Changes To Powder Properties As a Results Of Recyclingmentioning

confidence: 99%

“…Lu et al also observed a progression with the coarsening of the metal powder from 10 recycles to 30 recycles, as shown in Figure 5. [21] In contrast to these results, Gorji et al saw very little change in the PSD of 316L as it was recycled over 10 cycles, with a decrease in the average diameter (D 50 ) of the recycled powder by just 1 μm, falling from 26 to 25 μm. [22] When analyzing 316L powder recycled eight times, Sartin et al saw changes in the percentage volume of powder for different sieve sizes.…”

Section: Powder Size Distribution and Flowabilitymentioning

confidence: 87%

“…Lu et al quantified this increase in magnetism to show that the magnetization intensity increased from 0.0236 to 0.0967 emu g À1 for virgin and 30 times recycled powder, respectively. [21] Another factor is internal porosity, which may be present in gas-atomized powder before any changes could potentially occur due to the L-PBF process. [45] Internal porosity has also been reported in recycled 304L and 316L metal powder.…”

Section: Other Changesmentioning

confidence: 99%

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The Influence of Powder Reuse on the Properties of Laser Powder Bed‐Fused Stainless Steel 316L: A Review

et al. 2022

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There is a clear economic benefit for the recycling of metallic powder during additive manufacturing (AM). Laser powder bed fusion (L‐PBF) is one such AM process and research has found that the properties of the powder feedstock can change when the powder is reused through mechanisms such as spatter generation and alterations in chemistry. Such changes to powder properties can accumulate and may lead to significant differences in the mechanical properties of the final component. Often the changes to part properties are reasonably small; however, there is not currently enough understanding of the specific links between powder properties and the characteristics of the end component for the effects of powder recycling to be discounted. Herein, the typical lifecycle of stainless steel 316L powder in L‐PBF, the changes that occur to the powder feedstock, and the effects that this may have on the mechanical properties of components manufactured with recycled powder are reviewed.

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Section: Changes To Powder Properties As a Results Of Recyclingmentioning

confidence: 99%

“…Lu et al also observed a progression with the coarsening of the metal powder from 10 recycles to 30 recycles, as shown in Figure . [ 21 ]…”

Section: Changes To Powder Properties As a Results Of Recyclingmentioning

confidence: 99%

“…The PSD of virgin 316L powder compared to the same powder that has been recycled 10 and 30 times. [ 21 ] . The coarsening of the powder gradually shifts the peak of the PSD to the right.…”

Section: Changes To Powder Properties As a Results Of Recyclingmentioning

confidence: 99%

Section: Powder Size Distribution and Flowabilitymentioning

confidence: 87%

Section: Other Changesmentioning

confidence: 99%

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The Influence of Powder Reuse on the Properties of Laser Powder Bed‐Fused Stainless Steel 316L: A Review

et al. 2022

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Characterization and Microstructure of Recycled Eroded Particles from Die-Sink Electro Discharge Machining of H11 Alloy for Applicability in Additive Manufacturing

Voigt,

Wendler,

Siddique

et al. 2023

Met. Mater. Int.

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Different waste streams from electro discharge machining (EDM) were investigated for an upcycled usage in processes for additive manufacturing (AM). These erosion sludges accumulate in filter cartridges and at the bottom of machining basins. The enclosed particles were extracted, sieved and investigated via laser diffraction, dynamic image analysis, scanning electron microscopy, optical emission spectroscopy, elemental analysis and flowability measurements. Additionally, thermal, crystallographic and metallographic investigations as well as X-ray micro-computed tomography (µ-CT) were utilized for the characterization of particle and material properties. In general, eroded powders fulfill the requirements for AM regarding particle size and shape very well, which is confirmed in morphological investigations and powder flow characteristics showing similar properties as the H11 AM reference material. The chemical composition of the powders is equal to the machined H11 alloy, except for the high carbon content. Carbon is entrapped in the iron lattice originating from pyrolysis of the present dielectric fluid and the graphite electrode during rapid solidification, which leads to a transition from martensite to cementite structures. This change is observed in the microstructure of powders, in which acicular primary cementite and austenite are present. After remelting with slow heating and cooling rates the microstructure changed to ledeburite II with retained austenite and martensitic phases. The pore size and shape distributions obtained by µ-CT measurements showed a pore formation in the compact sample. These results provide a fundament of major properties as well as handling and recycling suggestions for eroded particles enclosed in waste sludges. Graphical Abstract

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Metal powder feedstock evaluation and management for powder bed fusion: a review of literature, standards, and practical guidelines

Gibbons

Govender

2023

Prog Addit Manuf

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Metal powders are key to metal additive manufacturing technologies such as powder bed fusion. These powder feedstocks experience a range of forces and physical phenomena both during the powder bed fusion process and additional post-processing stages that can alter their composition and material properties. To evaluate such effects, these powders need to be characterized, tested, and analyzed at critical stages of their lifecycles. This paper provides a review of the current state of the art for powder evaluation methods and their applicability for powder bed fusion production. Methods are categorized by the properties they evaluate, either particulate or bulk properties. Industry standards are identified for each method if applicable and the advantages and disadvantages of each are defined. Effects of these properties on the flowability and spreadability of powders are synthesized and practical management guidelines are defined. This paper aims at providing an overview of powder evaluation for powder bed fusion, practical considerations for the development of powder test and evaluation programs, and provide insights for future research undertakings in the field.

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A comprehensive characterization of virgin and recycled 316L powders during laser powder bed fusion

Cited by 11 publications

References 47 publications

The Influence of Powder Reuse on the Properties of Laser Powder Bed‐Fused Stainless Steel 316L: A Review

The Influence of Powder Reuse on the Properties of Laser Powder Bed‐Fused Stainless Steel 316L: A Review

Characterization and Microstructure of Recycled Eroded Particles from Die-Sink Electro Discharge Machining of H11 Alloy for Applicability in Additive Manufacturing

Metal powder feedstock evaluation and management for powder bed fusion: a review of literature, standards, and practical guidelines

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